Continuous counter-current organosolv processing of lignocellulosic feedstocks

ABSTRACT

A modular process for organosolv fractionation of lignocellulosic feedstocks into component parts and further processing of said component parts into one or more of a de-lignified cellulose stream, a sugar stream, small-chain alcohol streams and four structurally distinct classes of lignin derivatives. The modular process comprises a first processing module configured for digesting lignocellulosic feedstocks with an organic solvent thereby producing a cellulosic solids fraction and a liquid fraction, a second processing module configured for recovering small-chain alcohols and optionally a first class of lignin derivatives from the cellulosic solids fraction, a third processing module configured for recovering from the liquid fraction at least one of a second class and a third class of lignin derivatives or mixtures thereof, and waste stream comprising a fourth class of lignin derivatives. The fourth processing module may optionally recover the fourth class of lignin derivatives.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 12/324,311 filed Nov. 26, 2008, which is a continuation-in-partof application Ser. No. 12/016,932 filed Jan. 18, 2008, which is acontinuation-in-part of application Ser. No. 11/839,378 filed Aug. 15,2007, and claims the benefit of U.S. Provisional Application No.60/941,220 filed May 31, 2007.

FIELD OF THE INVENTION

This invention relates to fractionation of lignocellulosic feedstocksinto component parts. More particularly, this invention relates toprocesses, systems and equipment configurations for recyclableorganosolv fractionation of lignocellulosic material for controllableand manipulable production and further processing of lignins,monosaccharides, oligosaccharides, polysaccharides and other productsderived therefrom.

BACKGROUND OF THE INVENTION

Industrial processes for production of cellulose-rich pulps fromharvested wood are well-known and typically involve the steps ofphysical disruption of wood into smaller pieces and particles followedby chemical digestion under elevated temperatures and pressures todissolve and separate the lignins from the constituent cellulosicfibrous biomass. After digestion has been completed, the solidscomprising the cellulosic fibrous pulps are separated from the spentdigestion liquids which commonly referred to as black liquors andtypically comprise organic solvents, solubilized lignins, solid andparticulate monosaccarides, oligosaccharides, polysaccharides and otherorganic compounds released from the wood during the chemical digestion.The cellulosic fibrous pulps are typically used for paper manufacturingwhile the black liquors are usually processed to recover the heat valuein the soluble lignins and for recovery, purification and recycling ofthe solvents.

During the past two decades, those skilled in these arts have recognizedthat lignocellulosic materials including harvested gymnosperm andangiosperm substrates exemplified by chips and sawdust, woodyundercuttings and debris from forest plantations, annual and perennialfield crop residues, bagasse and other like types of herbaceous fibrousbiomass, waste paper wood products, waste materials and debris fromwood-processing operations, and the like, can be potentiallyfractionated using biorefining processes incorporating organosolvdigestion systems, into multiple useful component parts that can beseparated and further processed into high-value products such as fuelethanol, lignins, furfural, acetic acid, purified monosaccharide sugarsamong others (Pan et al., 2005, Biotechnol. Bioeng. 90: 473-481; Pan etal., 2006, Biotechnol Bioeng. 94: 851-861; Berlin et al., 2007, Appl.Biochem. Biotechnol. 136-140:267-280; Berlin et al., 2007, J. Chem.Technol Biotechnol. 82: 767-774). Organosolv pulping processes andsystems for lignocellulosic feedstocks are well-known and areexemplified by the disclosures in U.S. Pat. Nos. 4,941,944; 5,730,837;6,179,958; and 6,228,177. Although it appears that biorefining usingorganosolv systems has considerable potential for large-scale fuelethanol production, the currently available processes and systems arenot yet economically feasible because they require expensivepretreatment steps and currently produce only low-value co-products (Panet al., 2006, J. Agric. Food Chem. 54: 5806-5813; Berlin et al., 2007,Appl. Biochem. Biotechnol. 136-140:267-280; Berlin et al., 2007, J.Chem. Technol Biotechnol. 82: 767-774).

SUMMARY OF THE INVENTION

The exemplary embodiments of the present invention relate to systems,processes and equipment configurations for biorefining oflignocellulosic feedstocks into component parts which are thensubsequently separated. The separated component parts are furtherselectively, controllably and manipulably processed.

According to one exemplary embodiment of the present invention, there isprovided a modular biorefining processing system for receiving thereinand fractionating a lignocellulosic feedstock into component parts,separating the component parts into at least a solids fraction and aliquids fraction, and then separately processing the solids and liquidsfractions to further produce useful products therefrom. Suitable modularbiorefining processing systems of the present invention comprise atleast:

-   -   a first module comprising a plurality of equipment configured        for: (a) receiving and processing lignocellulosic fibrous        feedstocks, then (b) commingling under controlled temperature        and pressure conditions the processed feedstocks with suitable        solvents configured for physico-chemically disrupting the        lignocellulosic feedstock into a solids fraction comprising        mostly cellulosic pulps and a liquid fraction comprising spent        solvents containing therein at least lignins, lignin-containing        compounds, monosaccharides, oligosaccharides and polysaccarides,        dissolved and suspended solids comprising hemicelluloses and        celluloses and other organic compounds, and (c) providing a        first output stream comprising the cellulosic solids fraction        having a plurality of a first class of structurally distinct        lignin derivatives integrally but incidentally associated        therewith, and a second output stream comprising a black liquor        liquids fraction comprising spent organic solvents and        solubilized extractives therein comprising the three additional        structurally distinct classes of lignin derivatives.    -   a second processing module configured for receiving and        processing the cellulosic solids fraction, and recovering        therefrom at least a processed cellulose pulp stream;    -   a third processing module configured for separating the black        liquor liquids fraction into a partially de-lignified liquid        fraction and a first solids fraction comprising at least one of        a plurality of a second class of structurally distinct lignin        derivatives and a plurality of a third class of structurally        distinct lignin derivatives, and recovering from the partially        de-lignified liquid fraction at least a portion of the organic        solvent and a waste stream comprising a plurality of a fourth        class of structurally distinct lignin derivatives; and    -   a fourth processing module configured for recovery of a first        semi-solid waste material therefrom the waste stream.

According to another exemplary embodiment, the second processing modulemay be configured for receiving and de-lignifying the cellulosic solidsfraction with a suitable bleaching process and recovering a de-lignifiedcellulose pulp stream. Suitable bleaching processes are exemplified byelemental chlorine-free bleaching processes and total chlorine-freebleaching processes. The de-lignified cellulose pulp may be recoveredfor use as a highly purified cellulose feedstock in other industrialapplications. Alternatively, the cellulose pulp may be enzymaticallyhydrolyzed to produce a carbohydrates sugar stream that can be recoveredfor other industrial applications. Alternatively, the carbohydratessugar stream may fermented to produce short-chain alcohols that arerefinable into fuel-grade alcohols and industrial-grade alcoholsexemplified by ethanol and butanol.

According to another exemplary embodiment, the second processing modulemay be configured for enzymatically hydrolyzing the cellulosic solidsfraction to produce a carbohydrates sugar stream that fermented toproduce a fermentation beer from which is recovered short-chain alcoholsand a fluid waste stream. The short-chain alcohols are refinable intofuel-grade alcohols and industrial-grade alcohols exemplified by ethanoland butanol. The plurality of the first class of lignins derivatives maybe optionally recovered from the fluid waste stream.

Another exemplary embodiment relates to process and systemsmodifications to the second processing module to enable recovery atleast a portion of enzymes provided for enzymatic hydrolysis of thecellulosic solids stream, and for conditioning and recycling therecovered enzymes for additional hydrolysis of fresh cellulosic solidsstreams. Other exemplary embodiments relate to process and systemsmodifications configured for recovery of at least a portion of thefermenting microorganisms from fermentation vessels, conditioning andrecycling of the fermenting microorganisms for additional fermentationsof fresh carbohydrates sugar streams hydrolysed from the cellulosicsolids stream.

Other exemplary embodiments of the present invention relate toalternative process and systems configurations for the third processingmodule for separation and recovery of one or more pluralities ofstructurally distinct classes of lignins from the black liquor liquidsfraction, and for recovery of a fluid waste stream comprising aplurality of the fourth class of structurally distinct ligninderivatives. The fourth class of structurally distinct ligninderivatives are optionally recovered in the fourth processing module.

Another exemplary embodiment relates to an optional fifth processingmodule configured to receive therein at least one waste stream from atleast one of the second, third and fourth processing module, and toconvert the waste stream into a biogas, a fluid effluent and mineralsolids.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described in conjunction with reference tothe following drawings in which:

FIG. 1 is a schematic flowchart showing various exemplary embodiments ofthe present invention for modular biorefinery processing oflignocellulosic feedstocks for recovery of different product streams andvarious structural classes of lignin derivatives;

FIG. 2 is a schematic flowchart of an exemplary embodiment of thepresent invention of a modular continuous counter-flow system forprocessing a lignocellulosic feedstock;

FIG. 3 is a schematic flowchart of the system from FIG. 2 additionallyprovided with a device for optionally diverting the sugar output streamto (a) the fuel ethanol production module, and (b) an anaerobicdigestion module;

FIG. 4 is a schematic flowchart of an exemplary anaerobic digestionmodule suitable for cooperating with the modular continuous counter-flowsystem of the present invention for processing a lignocellulosicfeedstock;

FIG. 5 is schematic flowchart showing an alternative configuration ofthe fuel ethanol production module for concurrent saccharification andfermentation processes within a single vessel;

FIG. 6 is a schematic flowchart of a continuous counter-flow processingsystem of the process re-configured into a batch through-put system;

FIG. 7 is a schematic flowchart showing an alternative configuration forthe batch throughput system shown in FIG. 6;

FIG. 8 is a schematic flowchart showing an exemplary optional systemsdesign for a hybrid saccharification and fermentation module generallyconfigured for receiving and processing therein a cellulosic solidsstream according to an exemplary embodiment of the modular biorefineryof the present invention, wherein the optional systems design isconfigured for recovery and recycling of hydrolytic enzymes from asaccharification tank;

FIG. 9 is a schematic flowchart showing another exemplary optionalsystems design for a hybrid saccharification and fermentation modulegenerally configured for receiving and processing therein a cellulosicsolids stream according to an exemplary embodiment of the modularbiorefinery of the present invention, wherein the optional systemsdesign is configured for recovery and recycling of hydrolytic enzymesfrom a fermentation tank;

FIG. 10 is a schematic flowchart showing an exemplary optional systemsdesign for a simultaneous saccharification and fermentation modulegenerally configured for receiving and processing therein a cellulosicsolids stream according to an exemplary embodiment of the modularbiorefinery of the present invention, wherein the optional systemsdesign is configured for recovery and recycling of hydrolytic enzymesfrom a saccharification/fermentation tank;

FIG. 11 shows plots illustrating the simultaneous saccharification andfermentation (SSF) of organosolv-pretreated aspen (Populus tremula)chips: (a) % theoretical yield of ethanol produced from the resultantaspen pulps vs. time, and (b) the ethanol concentration in beers vs.time, produced during SSF of the aspen pulps;

FIG. 12 shows plots illustrating the SSF of organosolv-pretreatedBritish Columbian beetle-killed lodgepole pine (Pinus contorta) chips:(a) % theoretical yield of ethanol produced from the resultantbeetle-killed lodgepole pine pulps vs. time, and (b) the ethanolconcentration in beers vs. time, produced during SSF of the resultantbeetle-killed lodgepole pine pulps; and

FIG. 13 shows plots illustrating the simultaneous saccharification andfermentation (SSF) of organosolv-pretreated wheat straw and switchgrasslignocellulosic feedstocks: (a) % theoretical yield of ethanol producedfrom the resultant cellulosic pulps vs. time, and (b) the ethanolconcentration in beers vs. time, produced during SSF of the cellulosicpulps.

DETAILED DESCRIPTION OF THE INVENTION

Exemplary embodiments of the present invention relate to biorefiningsystems, processes and equipment configurations for receiving andcontrollably commingling lignocellulosic feedstocks with organicsolvents, thereby fractionating the lignocellulosic feedstocks intocomponent parts which are then subsequently separated. The separatedcomponent parts are further selectively, controllably and manipulablyprocessed. The exemplary embodiments of the present invention areparticularly suitable for separating out the lignocellulosic feedstocksinto a cellulosic solids stream comprising cellulose fibers having aplurality of a first class of structurally distinct lignin derivativesthat are integrally but incidentally associated therewith, and a blackliquor liquid stream comprising a mixture of spent organic solvents andsolubilized extractives from the lignocellulosic feedstocks. Thesolubilized extractives include pluralities of three additionalstructurally distinct classes of lignin derivatives. Also provided areprocesses and systems for separating the cellulosic solids stream intoone or more of a de-lignified cellulose pulp stream and a carbohydratesstream. The processes and systems may be additionally configured forconversion of one or more of the cellulosic solids stream, thede-lignified cellulose pulp stream, and the carbohydrates stream into ashort-chain alcohol stream, e.g., an ethanol stream. Also are providedprocesses and systems for recovery of at least a portion of the organicsolvents from the black liquor stream, and optionally, for separatingand recovering one or more of the three additional structurally distinctclasses of lignin derivatives, and further separating therefrom theprocessed black liquor stream one or more of furfurals, acetic acid,and/or carbohydrates sugar streams.

Those skilled in these arts will understand that biorefining pertains tothe integration of biomass conversion processes and equipment to producemultiple products including fuels, chemicals, thermal energy andelectrical power from a biomass feedstock. By concurrently producingmultiple products, a biorefinery can take advantage of the differencesin biomass components and intermediates, and maximize the values derivedfrom different types and qualities of feedstocks. Furthermore,concurrent production of multiple products enables controllable directedmanipulation of process subcomponents to preferentially produce more ofcertain selected products while concurrently producing less of otherproducts.

An exemplary embodiment of the present invention relates to subdividinga biorefinery system into smaller parts (i.e., modules or components)that are interconnected but are configured such that each module can beindependently created, and separately and controllably operated.However, the interconnections between the modules enable controllablydirected delivery of process inputs into the individual modules, and thecontrollable egress and transfer of process outputs from the individualmodules to other modules. For clarity, each module comprising abiorefinery system according to the present module is configured toreceive and process therein at least one input feedstock therebyproducing at least two or more product output streams. Each productoutput stream from one module may be transferred to a second module asan input feedstock wherein it is converted into two or more new productoutput streams. The configurations of each module and theinterconnections between the module enable targeted and controllablerecovery of some or all of each product output stream from a selectedmodule, or alternatively, transfer of some or all of each product outputstream from the selected module to another module, thereby enabling themodular biorefinery to drive different but integrated functionalities.The exemplary modular biorefineries of the present invention arecharacterized by functional partitioning into discrete scalable,reusable modules consisting of isolated, self-contained functionalelements, rigorous use of well-defined modular interfaces includingobject-oriented descriptions of module functionality, ease of change toachieve technology transparency and, make use of industry standards forkey interfaces. In addition to flexibility in design, modularization ofbiorefining systems enables additing on additional modules to furtherprocess product output streams thereby creating addition product captureopportunities, and also enables by-passing one or more processingmodules if so desired.

An exemplary embodiment of a modular biorefinery system according topresent invention, for processing lignocellulosic feedstocks maycomprise four modules wherein the first module is configured to receiveand process therein with a solvent, a lignocellulosic feedstock toproduce a cellulosic solids output and a liquid extractives output. Thecellulosic solids output from the first module is transferable as afeedstock into a second module wherein the feedstock is converted into arecoverable ethanol stream and a waste stream. The liquid extractivesoutput from the first module is transferable as feedstock into a thirdmodule wherein a portion of the solvent is recovered from feedstock andrecycled back into the first module. The de-solventized feedstock in thethird module may be further processed to precipitate and recovertherefrom a target extractive product thereby producing a refined liquidproduct output. The refined liquid product output is transferable into afourth module for option recovery of one or more additional extractives.An optional fifth module may be provided to receive and process thereinone ore more of the waste stream from the second module, the refinedliquid product output from the third module, and one or more productstreams from the fourth module.

An exemplary modular processing system of the present invention is shownin FIG. 1 and generally comprises four modules A-D wherein the firstmodule A is configured for receiving and processing lignocellulosicfeedstocks with at least one organic solvent whereby the processedlignocellulosic feedstocks are separable into a cellulosic solidsfraction comprising cellulose fibers and the first class of ligninderivatives integrally but incidentally associated therewith, and ablack liquor liquids fraction comprising spent organic solvents andsolubilized extractives therein comprising the three additional classesof lignin derivatives.

The second module B is configurable for receiving the cellulosic solidsfraction discharged from the first module A and for recovering therefromat least one of a cellulose pulp stream, a carbohydrates stream, anethanol stream, and optionally, the first class of lignin derivatives.The first class of lignin derivatives is integrally associated with thecellulose fibres and originate from native lignin polymers producedduring plant growth and development. This first class of ligninderivatives comprises a plurality of relatively very high molecularweight lignin fractions derived during organosolv solubilization of thenative lignin polymers during the processing of the lignocellulosicfeedstocks in the first module A. This first class of lignin derivativesis referred to hereafter as a very high molecular weight class of ligninderivatives (i.e., VHMW lignin).

The third module C is configurable for receiving the black liquor liquidstream from the first module A and for recovering therefrom at least aportion of the spent organic solvent and at least some of the threeadditional structurally distinct classes of lignin derivatives. Thesecond class of lignin derivatives comprises a plurality of relativelyhigh molecular weight lignin structures that are released by organosolvsolubilization of the native lignin polymers during the processing ofthe lignocellulosic feedstocks in the first module A. The second classof lignin derivatives is referred to hereafter as a high molecularweight class of lignin derivatives (i.e., HMW lignin). HMW ligninderivatives have a tendency to self-precipitate from the black liquorliquid stream if it is cooled upon egress from the first module A. Thethird class of lignin derivatives comprises a plurality of relativelymedium molecular weight lignin structures that are derived duringorganosolv solubilization of the native lignin polymers during theprocessing of the lignocellulosic feedstocks in the first module A, andis referred to hereafter as a medium molecular weight class of ligninderivatives (i.e., MMW lignin). MMW lignin derivatives may beprecipitated from the black liquor liquid stream by copious dilution ofthe black liquor with water. Module C may be optionally configured forco-precipitation of the HMW lignin derivatives with the MMW derivativesby maintaining the black liquor liquid fraction at elevated temperatureswhile rapidly diluting the black liquor with copious amounts of water,thereby enabling recovery of precipitated solids comprising a mixture ofpluralities of HMW lignin derivatives and MMW lignin derivatives. Theprecipitated HMW lignin derivatives, MMW lignin derivatives, andmixtures of HMW lignin derivatives co-precipitated with MMW ligninderivatives are separable from the processed black liquor liquid streamswith standard chemical processing equipment and systems known to thoseskilled in these arts. Suitable separation equipment is exemplified bydecanter centrifuges and filtration systems. Spent organic solvents maybe recovered from the de-lignified black liquor solutions bydistillation, with concurrent recovery of furfurals if so desired. Theresulting stillage comprises extractives and the fourth class of ligninderivatives that are composed of very-low molecular weight ligninstructures that are derived during organosolv solubilization of thenative lignin polymers during the processing of the lignocellulosicfeedstocks in the first module A. The fourth class of lignin derivativesis referred to hereafter as a very low molecular weight class of ligninderivatives (i.e., VLMW lignin). The stillage comprising the processedblack liquor remaining after recovery of the organic solvents in thesecond module C may be further processed in the fourth module D forseparation and recovery therefrom of one or more of the extractivessolubilized from the lignocellulosic feedstock in the first module A.

The fourth module D is configurable for receiving and separating thestillage from the third module C into one or more of acetic acid, VLMWlignin derivatives, a sugar syrup stream, and a semi-solid/solid wastematerial.

An additional exemplary embodiment of the present invention relates toan optional fifth module E configurable for receiving therein thesemi-solid/solid waste material from the fourth module D and foranaerobically digesting the material into collectible biogas, water andmineral solids components. The fifth module E may also receive thereinthe processed black liquor stillage from the third module C and foranaerobically digesting the stillage into collectible biogas, water andmineral solids components.

Another additional exemplary embodiment of the present invention relatesto an optional sixth module F configurable for receiving therein thesugar syrup stream from the fourth module D, and for fermenting and thendistilling therein sugar syrup stream. A 1,3-propanediol component isseparable from the distillate. At least a lactic acid component isseparable from the stillage separated from the 1,3-propanedioldistillage.

An illustrative exemplary modular processing system of the presentinvention in shown in FIG. 2, wherein the first module A is providedwith a bin 10 configured for receiving and temporarily storinglignocellulosic feedstocks while continually discharging the feedstockinto a conveyance system provided with a separating device 20 configuredfor removing pebbles, gravel, metals and other debris. A suitableseparating device is a screening apparatus. The separating device 20 maybe optionally configured for sizing the lignocellulosic feedstock intodesired fractions. The processed lignocellulosic feedstock is thenconveyed with a first auger feeder 30 into a first end of adigestion/extraction vessel 40 and then towards the second end of thedigestion/extraction vessel 40. The vessel 40 is provided with an inletapproximate the second end for receiving a pressurized stream of asuitable heated digestion/extraction solvent which then counterflowsagainst the movement of the lignocellulosic feedstock through the vessel40 thereby providing turbulence and commingling of the solvent with thefeedstock. Alternatively, the inlet for receiving the pressurized streamof heated digestion/extraction solvent may be provided about the firstend of the digestion/extraction vessel 40 or further alternatively,interposed the first and second ends of the digestion/extraction vessel40. It is suitable to use organic solvents for the processes of thepresent invention. Exemplary suitable organic solvents include methanol,ethanol, propanol, butanol, acetone, and the like. If so desired, theorganic solvents may be additionally controllably acidified with aninorganic or organic acid. If so desired, the pH of the organic solventsmay be additionally controllably manipulated with an inorganic ororganic base. The vessel 40 is controllably pressurized and temperaturecontrolled to enable manipulation of pressure and temperature so thattarget cooking conditions are provided while the solvent is comminglingwith the feedstock. Exemplary cooking conditions include pressures inthe range of about 15-40 bar (g), temperatures in the range of about120-350° C., and pHs in the range of about 0.5-5.5. During the cookingprocess, lignins and lignin-containing compounds contained within thecommingled and impregnated lignocellulosic feedstock will be dissolvedinto the organic solvent resulting in the cellulosic fibrous materialspreviously adhered thereto and therewith to disassociate and to separatefrom each other. Those skilled in these arts will understand that inaddition to the dissolution of lignins and lignin-containing polymers,the cooking process will release monosaccharides, oligosaccharides andpolysaccharides and other organic compounds for example acetic acid,furfural, 5-hydroxymethyl furfural (5-HMF), other organic acids such asformic and levulinic acids in solute and particulate forms, from thelignocellulosic materials into the organic solvents. Those skilled inthese arts refer to such organic solvents containing the lignins,lignin-containing compounds, monosaccharides, oligosaccharides,polysaccharides, hemicelluloses and other organic compounds extractedfrom the lignocellulosic feedstock, as “black liquors” or “spentliquors”. The disassociated cellulosic fibrous materials released fromthe feedstock are conveyed to the second end of the vessel 40 where theyare discharged via a second auger feeder 50 which compresses thecellulosic fibrous materials into a solids fraction, i.e., a pulp whichis then conveyed to the second module B. The black liquors aredischarged as a liquid fraction from about the first end of thedigestion/extraction vessel 40 into a pipeline 47 for conveyance to thethird module C.

The second module B is provided with a mixing vessel 60 wherein theviscosity of solids fraction, i.e., pulp discharged from the firstmodule A is controllably reduced to a selected target viscosity, bycommingling with a recovered recycled solvent stream delivered by apipeline 130 from a down-stream component of module B. The reducedviscosity pulp is then transferred to a digestion vessel 70 where asuitable enzymatic preparation is intermixed and commingled with thepulp for progressively breaking down the cellulosic fibers, suspendedsolids and dissolved solids into hemicelluloses, other polysaccharides,oligosaccharides and monosaccharides. A liquid stream comprising thesedigestion products is transferred from the digestion vessel 70 to afermentation vessel 80 and is commingled with a suitable microbialinoculum selected for fermentation of hexose and pentose monosaccharidesand/or oligosaccharides in the liquid stream thereby producing afermentation beer comprising at least a short-chain alcohol exemplifiedby ethanol, residual sediments and lees. The fermentation beer istransferred to a first distillation tower 90 for refining byvolatilizing then distilling and separately collecting from the top ofthe distillation tower 90 an ethanol stream which is transferred andstored in a suitable holding container 100. The ethanol stream may befurther refined, for example by distillation, into one or more of afuel-grade ethanol stream, an industrial-grade ethanol stream, and apotable ethanol stream. The remaining liquid stillage is optionallyremoved from the bottom of distillation tower 90 to equipment 110configured to precipitate and separate VHMW lignins which are thencollected and stored in a suitable vessel 120 for further processingand/or shipment. It is within the scope of the present invention to heatthe stillage and flash it with cold water to facilitate precipitation ofthe VHMW lignins. The detoxified stillage may then be controllablyrecycled from equipment 110 via pipeline 130 to the mixing vessel 60 forreducing the viscosity of fresh incoming pulp from the first module A.However, the remaining liquid stillage may be optionally recovered if sodesired, for alternative processing and/or disposal without firstseparating and recovering therefrom the plurality of VHMW ligninderivatives.

Suitable enzyme preparations for addition to digestion vessel 70 forprogressively breaking down cellulosic fibers into hemicelluloses,polysaccharides, oligosaccharides and monosaccharides may comprise oneor more of enzymes exemplified by endo-β-1,4-glucanases,cellobiohydrolases, β-glucosidases, β-xylosidases, xylanases,α-amylases, 13-amylases, pullulases, esterases, other hemicellulases andcellulases and the like.

Suitable microbial inocula for fermenting pentose and/or hexosemonosaccharides in fermentation vessel 80 may comprise one or moresuitable strains selected from yeast species, fungal species andbacterial species. Suitable yeasts are exemplified by Saccharomyces spp.and Pichia spp. Suitable Saccharomyces spp are exemplified by S.cerevisiae such as strains Sc Y-1528, Tembec-1 and the like. Suitablefungal species are exemplified by Aspergillus spp. and Trichoderina spp.Suitable bacteria are exemplified by Escherichia coli, Zymomonas spp.,Clostridium spp., and Corynebacterium spp. among others, naturallyoccurring and genetically modified. It is within the scope of thepresent invention to provide an inoculum comprising a single strain, oralternatively a plurality of strains from a single type of organism, orfurther alternatively, mixtures of strains comprising strains frommultiple species and microbial types (i.e. yeasts, fungi and bacteria).

The black liquors discharged as a liquid fraction from thedigestion/extraction vessel 40 of third module A, are processed inmodule C to recover at least a portion of the digestion/extractionsolvent comprising the black liquors, and to separate useful componentsextracted from the lignocellulosic feedstocks as will be described inmore detail below. The HMW lignin derivatives have a tendency toself-precipitate from the black liquor liquid stream as it cools uponegress from the first module A, and therefore may be separated from theblack liquor liquid stream by a suitable solids-liquids separationequipment 150 as exemplified by filtering apparatus, hydrocycloneseparators, centrifuges and other such equipment known to those skilledin these arts. It is suitable to provide cooling to the black liquorliquid egress lines to facilitate the self-precipitation of the HMWlignins. The partially de-lignified black liquor liquid stream egressingfrom the solids-liquids separation equipment 150 is transferred into aheating tower 140 wherein it is first heated then transferred to mixingtank 160 wherein it is rapidly mixed (i.e., “flashed”) and commingledwith a supply of cold water thereby precipitating MMW lignins from thepartially de-lignified black liquor. The precipitated MMW lignins areseparated from the water-diluted black liquor liquid stream by asuitable solids-liquids separation equipment 165 as exemplified byfiltering apparatus, hydrocyclone separators, centrifuges and other suchequipment. The separated MMW lignins are transferred to a lignin drier165 for controlled removal of excess moisture, after which the dried MMWlignins are transferred to a storage bin 170 for packaging and shipping.The de-lignified filtrate egressing from the solids-liquids separationequipment 165 is transferred to a second distillation tower 180 forvaporizing, distilling and recovering therefrom at least a portion ofthe organic solvents used for fractionating the lignocellulosicfeedstocks, remaining therein. In the case where short-chain alcoholsexemplified by ethanol are used for fractionating the lignocellulosicfeedstocks, the recovered organic solvent will comprise ethanol, and istransferred to a digestion/extraction solvent holding tank 250 where itmay, if so desired, be commingled with a portion of ethanol produced inmodule B and drawn from pipeline 95, to controllably adjust theconcentration and composition of the digestion/extraction solvent priorto supplying the digestion/extraction solvent via pipeline 41 to thedigestion/extraction vessel 40 of module A. It is within the scope ofthe present invention to recover furfurals from the de-lignifiedfiltrate fraction concurrent with the vaporization and distillationprocesses within the second distillation tower, and to transfer therecovered furfurals to a storage tank 190. An exemplary suitable processfor recovering furfurals is to acidify the heated de-lignified filtratethereby condensing furfurals therefrom. It is within the scope of thepresent invention to supply suitable liquid bases or acids tocontrollably adjust the pH of the de-lignified filtrate fraction.Suitable liquid bases are exemplified by sodium hydroxide. Suitableacids are exemplified by sulfuric acid.

The stillage from the second distillation tower 180 is transferred tothe fourth module D for further processing and separation of usefulproducts therefrom. The hot stillage may be transferred into a coolingtower 200 configured to collect a condensate comprising acetic acidwhich is then transferred to a suitable holding vessel 210. Thede-acidified stillage may then transferred to a stillage processingvessel 220 configured for heating the stillage followed by flashing withcold water thereby precipitating VLMW lignins which are then separatedfrom a sugar syrup stream, and a semi-solid/solid waste materialdischarged into a waste disposal bin 226. The VLMW lignins aretransferred to a suitable holding container 230 for further processingand/or shipment. The sugar syrup stream, typically comprising at leastone of xylose, arabinose, glucose, mannose and galactose, is passedthrough a decanter 240 which separates VLMW lignins from the sugar syrupstream thereby purifying the sugar syrup stream which is transferred toa suitable holding tank 247 prior to further processing and/or shipping,The VLMW lignins are transferred to a suitable holding tank 245 prior tofurther processing and/or shipping. It is within the scope of thepresent invention to divert from the fourth module D some or all of thestillage recovered from the second distillation tower 180 in the thirdmodule C, for suitable disposal thereof or alternatively, for processingby anaerobic digestion.

FIG. 3 illustrates exemplary modifications that are suitable for themodular lignocellulosic feedstock processing system of the presentinvention.

One exemplary embodiment includes provision of a pre-treatment vessel 25for receiving therein processed lignocellulosic feedstock from theseparating device 20 for pre-treatment prior to digestion and extractionby commingling and saturation with a heated digestion/extraction solventfor a suitable period of time. A suitable supply of digestion/extractionsolvent may be diverted from pipeline 41 by a valve 42 and delivered tothe pre-treatment vessel 25 by pipeline 43. Excess digestion/extractionsolvent is squeezed from the processed and pre-treated lignocellulosicfeedstock by the mechanical pressures applied by the first auger feeder30 during transfer of the feedstock into the digestion/extraction vessel40. The extracted digestion/extraction solvent is recyclable viapipeline 32 back to the pre-treatment vessel 25 for commingling withincoming processed lignocellulosic feedstock and fresh incomingdigestion/extraction solvent delivered by pipeline 43. Suchpre-treatment of the processed lignocellulosic feedstock prior to itsdelivery to the digestion/extraction vessel 40 will facilitate the rapidabsorption of digestion/extraction solvent during the commingling andcooking process and expedite the digestion of the lignocellulosicfeedstock and extraction of components therefrom.

Another exemplary embodiment illustrated in FIG. 2 provides a seconddiverter valve 260 interposed the sugar syrup stream discharged from thedecanter 240 in module D. In addition to directing the sugar stream tothe sugar stream holding tank 240, the second diverter valve 260 isconfigured for controllably diverting a portion of the liquid sugarstream into a pipeline 270 for delivery into the fermentation tank 80 inmodule B. Such delivery of a portion of the liquid sugar stream frommodule D will enhance and increase the rate of fermentation in tank 80and furthermore, will increase the volume of ethanol produced from thelignocellulosic feedstock delivered to module A.

Another exemplary embodiment illustrated in FIG. 2 provides an optionalfifth module E comprising an anaerobic digestion system configured toreceive semi-solid/solid wastes from the stillage processing vessel 220and optionally configured for receiving a portion of the sugar syrupstream discharged from the stillage processing vessel 220. An exemplaryanaerobic digestion system comprising module E of the present inventionis illustrated in FIG. 4 and generally comprises a sludge tank 310, avessel 320 configured for containing therein biological acidificationprocesses (referred to hereinafter as an acidification vessel), a vessel330 configured for containing therein biological acetogenesis processes(referred to hereinafter as an acetogenesis vessel), and a vessel 340configured for containing therein biological processes for conversion ofacetic acid into biogas (referred to hereinafter as a biogas vessel).The semi-solid/solid waste materials produced in the stillage processingvessel 220 of module C are transferred by a conveyance apparatus 225 tothe sludge tank 310 wherein anaerobic conditions and suitablepopulations of facultative anaerobic microorganisms are maintained.Enzymes produced by the facultative microorganisms hydrolyze the complexorganic molecules comprising the semi-solid/solid waste materials intosoluble monomers such as monosaccharides, amino acids and fatty acids.It is within the scope of the present invention to provide if so desiredinocula compositions for intermixing and commingling with thesemi-solid/solid wastes in the sludge tank 310 to expedite thehydrolysis processes occurring therein. Suitable hydrolyzing inoculacompositions are provided with at least one Enterobacter sp. A liquidstream containing therein the hydrolyzed soluble monomers is transferredinto the acidification vessel 320 wherein anaerobic conditions and apopulation of acidogenic bacteria are maintained. The monosaccharides,amino acids and fatty acids contained in the liquid stream received bythe acidification vessel 320 are converted into volatile acids by theacidogenic bacteria. It is within the scope of the present invention toprovide if so desired acidification inocula compositions configured forfacilitating and expediting the production of solubilized volatile fattyacids in the acidification tank 320. Suitable acidification inoculacompositions are provided with at least one of Bacillus sp.,Lactobacillus sp. and Streptococcus sp. A liquid stream containingtherein the solubilized volatile fatty acids is transferred into theacetogenesis vessel 330 wherein anaerobic conditions and a population ofacetogenic bacteria are maintained. The volatile fatty acids areconverted by the acetogenic bacteria into acetic acid, carbon dioxide,and hydrogen. It is within the scope of the present invention to provideif so desired inocula compositions configured for facilitating andexpediting the production of acetic acid from the volatile fatty acidsdelivered in the liquid stream into in the acetogenesis vessel 330.Suitable acetification inocula compositions are provided with at leastone of Acetobacter sp., Gluconobacter sp., and Clostridium sp. Theacetic acid, carbon dioxide, and hydrogen are then transferred from theacetogenesis vessel 330 into the biogas vessel 340 wherein the aceticacid is converted into methane, carbon dioxide and water. Thecomposition of the biogas produced in the biogas vessel 330 of module Ewill vary somewhat with the chemical composition of the lignocellulosicfeedstock delivered to module A, but will typically comprise primarilymethane and secondarily CO₂, and trace amounts of nitrogen gas,hydrogen, oxygen and hydrogen sulfide. It is within the scope of thepresent invention to provide if so desired methanogenic inoculacompositions configured for facilitating and expediting the conversionof acetic acid to biogas. Suitable methanogenic inocula compositions areprovided with at least one of bacteria are from the Methanobacteria sp.,Methanococci sp., and Methanopyri sp. The biogas can be fed directlyinto a power generation system as exemplified by a gas-fired combustionturbine. Combustion of biogas converts the energy stored in the bonds ofthe molecules of the methane contained in the biogas into mechanicalenergy as it spins a turbine. The mechanical energy produced by biogascombustion, for example, in an engine or micro-turbine may spin aturbine that produces a stream of electrons or electricity. In addition,waste heat from these engines can provide heating for the facility'sinfrastructure and/or for steam and/or for hot water for use as desiredin the other modules of the present invention.

However, a problem with anaerobic digestion of semi-solid/solid wastematerials is that the first step in the process, i.e., the hydrolysis ofcomplex organic molecules comprising the semi-solid/solid wastematerials into a liquid stream containing soluble monomers such asmonosaccharides, amino acids and fatty acids, is typically lengthy andvariable, while the subsequent steps, i.e., acidification,acetification, and biogas production proceed relatively quickly incomparison to the first step. Consequently, such lengthy and variablehydrolysis in the first step of anaerobic may result in insufficientamounts of biogas production relative to the facility's requirements forpower production and/or steam and/or hot water. Accordingly, anotherembodiment of the present invention, as illustrated in FIGS. 3 and 4,controllably provides a portion of the sugar syrup stream dischargedfrom the stillage processing vessel 220 of module D, to theacidification tank 320 of module E to supplement the supply of solublemonosaccharides and/or oligosaccharides hydrolyzed from semi-solid/solidmaterials delivered to the sludge tank 310. Thus, the amount of biogasproduced by module E of the present invention can be preciselymanipulated and modulated by providing a second diverter 260 interposedthe sugar syrup discharge line from stillage processing vessel 220, tocontrollably divert a portion of the sugar syrup into pipeline 275 fortransfer to the acidification vessel 320.

Another exemplary embodiment of the present invention is illustrated inFIG. 5 and provides an optional vessel 280 for module B, wherein vessel280 is configured for receiving the reduced viscosity pulp from mixingvessel 60 (FIGS. 2, 3) and for concurrent i.e., co-saccharification andco-fermentation therein of the reduced-viscosity solids fractions. Thoseskilled in these arts will understand that such co-saccharification andco-fermentation processes are commonly referred to as “simultaneoussaccharification and fermentation” (SSF) processes, and that vessel 280(referred to hereinafter as a SSF vessel) can replace digestion vessel70 and fermentation vessel 80 shown in FIGS. 2 and 3. It is suitable toprovide a supplementary stream of sugar syrup into the SSF vessel 280via pipeline 270 from the second diverter valve 260 (FIGS. 2 and 5) tocontrollably enhance and increase the rate of fermentation in the SSFvessel 280.

Another exemplary embodiment of the present invention is illustrated inFIG. 6 and provides an alternative first module AA, for communicationand cooperation with modules B and C, wherein the alternative firstmodule AA (FIG. 6) is configured for receiving, processing anddigestion/extraction of batches of a lignocellulosic feedstock, ascompared to module A which is configured for continuous inflow,processing and digestion/extraction of a lignocellulosic feedstock (FIG.2). As shown in FIG. 6, one exemplary embodiment for batchdigestion/extraction of a lignocellulosic feedstock comprises a batchdigestion/extraction vessel 400 interconnected and communicating with adigestion/extraction solvent re-circulating tank 410 and a solvent pump420. A batch of lignocellulosic feedstock is loaded into a receiving bin430 from where it is controllably discharged into a conveyance systemprovided with a screening device 440 configured for removing pebbles,gravel, metals and other debris. The screening device 440 may beoptionally configured for sizing the lignocellulosic feedstock intodesired fractions. The processed lignocellulosic feedstock is thenconveyed with a third auger feeder 450 into a first end of the batchdigestion/extraction vessel 400. The digestion/extraction solventre-circulating tank 410 is configured to receive a suitabledigestion/extraction solvent from the digestion/extraction solventholding tank 250 of module B via pipeline 41. The digestion/extractionsolvent is pumped via solvent pump 420 into the batchdigestion/extraction vessel 400 wherein it controllably commingled,intermixed and circulated through the batch of lignocellulosic feedstockcontained therein. The batch digestion/extraction vessel 400 iscontrollably pressurized and temperature controlled to enablemanipulation of pressure and temperature so that target cookingconditions are provided while the solvent is commingling and intermixingwith the feedstock. Exemplary cooking conditions include pressures inthe range of about 15-30 bar(g), temperatures in the range of about120°-350° C., and pHs in the range of about 1.5-5.5. During the cookingprocess, lignins and lignin-containing compounds contained within thecommingled and impregnated lignocellulosic feedstock will be dissolvedinto the organic solvent resulting in the cellulosic fibrous materialsadhered thereto and therewith to disassociate and to separate from eachother. Those skilled in these arts will understand that in addition tothe dissolution of lignins and lignin-containing polymers, the cookingprocess will release monosaccharides, oligosaccharides andpolysaccharides and other organic compounds for example acetic acid, insolute and particulate forms, from the lignocellulosic materials intothe organic solvents. It is suitable to discharge thedigestion/extraction solvent from the batch digestion/extraction vessel400 through pipeline 460 during the cooking process for transfer viapipeline 460 back to the digestion/extraction solvent re-circulatingtank 410 for re-circulation by the solvent pump 420 back into the batchdigestion/extraction vessel 400 until the lignocellulosic feedstock issuitable digested and extracted into a solids fraction comprising aviscous pulp material comprising dissociated cellulosic fibers, and aliquids fraction, i.e., black liquor, comprising solubilized lignins andlignin-containing polymers, hemicelluloses, other polysaccharides,oligosaccharides, monosaccharides and other organic compounds in soluteand particulate forms, from the lignocellulosic materials in the spentorganic solvents. It is within the scope of the present invention towithdraw a portion of the re-circulating digestion/extraction solventfrom the solvent re-circulating tank 410 via pipeline 465 for transferto the heating tower 140 in module C, and to replace the withdrawnportion of re-circulating digestion/extraction solvent with freshdigestion/extraction solvent from the digestion/extraction solventholding tank 250 of module B via pipeline 41, thereby expediting thedigestion/extraction processes within the batch digestion/extractionvessel 400. After digestion/extraction of the lignocellulosic feedstockhas been completed, the solids fraction comprising cellulosic fibre pulpis discharged from the batch digestion/extraction vessel 400 andconveyed to the mixing vessel 60 in module B wherein the viscosity ofthe solids fraction, i.e., pulp discharged from the first module AA, iscontrollably reduced to a selected target viscosity by commingling andintermixing with de-lignified stillage delivered via pipeline 130 thenbe controllably recycled from de-lignification equipment 110 of module Bafter which the reduced-viscosity pulp is further processed bysaccharification, fermentation and refining as previously described. Theblack liquor is transferred from the digestion/extraction solventre-circulating tank 410 via pipeline 465 to the heating tower 140 inmodule C for precipitating lignin therefrom and further processing aspreviously described.

A suitable exemplary modification of the batch digestion/extractionmodule component of the present invention is illustrated in FIG. 7,wherein a pre-treatment vessel 445 is provided for receiving thereinprocessed lignocellulosic feedstock from the screening device 440 forpre-treatment prior to conveyance to the batch digestion/extractionvessel 400, by commingling and saturation with a digestion/extractionsolvent for a suitable period of time. A suitable supply ofdigestion/extraction solvent may be diverted from pipeline 41 by a valve42 (shown in FIG. 3) and delivered to the pre-treatment vessel 445 bypipeline 43. Excess digestion/extraction solvent is squeezed from theprocessed and pre-treated lignocellulosic feedstock by the mechanicalpressures applied by the third auger feeder 450 during transfer of thefeedstock into the batch digestion/extraction vessel 400. The extracteddigestion/extraction solvent is recyclable via pipeline 455 back to thepre-treatment vessel 445 for commingling with incoming processedlignocellulosic feedstock and fresh incoming digestion/extractionsolvent delivered by pipeline 43. Such pre-treatment of the processedlignocellulosic feedstock prior to its delivery to the batchdigestion/extraction vessel 400 will facilitate the rapid absorption ofdigestion/extraction solvent during the commingling and cooking processand expedite the digestion of the lignocellulosic feedstock andextraction of components therefrom.

Another exemplary embodiment of the present invention relates toprocesses, systems and equipment configured for de-lignifying from thecellulosic solids stream recovered from the first module A, theplurality of VHMW lignin derivatives that are integrally butincidentally associated therewith the cellulosic solids stream afterfractionation of the lignocellulosic feedstocks with one or more organicsolvents has been completed in the first module A, and the cellulosicsolids stream has been separated from the black liquor liquid stream.According to one aspect, the second module B may be optionallyconfigured to receive and delignify the cellulosic solids streamseparated from the first module A, by bleaching the pulp with anadaptation of one of an elemental chlorine-free (ECF) process or a totalchlorine-free (TCF) process. An exemplary suitable ECF process compriseswashing the cellulosic solids stream with 3%-4% chlorine dioxide at atemperature selected from the range of about 60° C. to about 80° C.,followed by a wash with a dilute alkali solution at a temperatureselected from the range of about 45° C. to about 90° C., followed by asecond wash with 3-4% chlorine dioxide at a temperature selected fromthe range of about 60° C. to about 80° C. thereby producing ade-lignified cellulose pulp which is washed several times with warmwater. It is optional to wash the pulp with warm water between each ofthe de-lignification washes. It is also optional to commingle ozone withchlorine dioxide in one of the de-lignifying washing step. It is alsooptional to perform the dilute alkali wash inside a vessel pressurizedwith oxygen. An exemplary suitable TCF process comprises washing thecellulosic solids stream with a mild alkali solution at a temperatureranging from about 60° C. to about 80° C. in a vessel pressurized withoxygen, followed by at least two washes with hydrogen peroxide, therebyproducing a de-lignified cellulose pulp. It is optional to wash thecellulose pulp with warm water between each of the de-lignificationwashes. The de-lignified cellulose pulp may be recovered from the secondmodule B for further processing to configure cellulose-comprisingcompositions. In this exemplary embodiment, the second module B may beadditionally configured for collecting the spent de-lignificationwashings and water washing, and recovering at least a portion of theplurality of VHMW lignin derivatives de-lignified from the cellulosicsolids stream.

Another exemplary embodiment of the present invention relates toadditional processes, systems and equipment configurations provided inthe second module B configured for de-lignifying the cellulosic solidsstream recovered from the first module A, wherein the de-lignifiedcellulose pulp is controllably separated by enzymatic hydrolysis into acarbohydrates stream comprising at least monosaccharides. Suitableenzymes are exemplified by endo-β-1,4-glucanases, cellobiohydrolases,β-glucosidases, cellulases, and the like. The carbohydrates stream maybe recovered from the second module B as a final product stream.Alternatively, the carbohydrates stream may be fermented in a suitablefermentation vessel to produce a short-chain alcohol stream exemplifiedby butanol and ethanol. The short-chain alcohol stream may be furtheredrefined, for example by distillation, into one or more of a fuel-gradeshort-chain alcohol stream, an industrial-grade short-chain alcoholstream, and if the short-chain alcohol stream is an ethanol stream, intoa potable ethanol stream. Suitable microbial inocula for fermenting suchcarbohydrate streams may comprise one or more suitable strains selectedfrom yeast species, fungal species and bacterial species. Suitableyeasts are exemplified by Saccharomyces spp. and Pichia spp. SuitableSaccharomyces spp are exemplified by S. cerevisiae such as strains ScY-1528, Tembec-1 and the like. Suitable fungal species are exemplifiedby Aspergillus spp. and Trichoderma spp. Suitable bacteria areexemplified by Escherichia coli, Zymomonas spp., Clostridium spp., andCorynebacterium spp. among others, naturally occurring and geneticallymodified. It is within the scope of the present invention to provide aninoculum comprising a single strain, or alternatively a plurality ofstrains from a single type of organism, or further alternatively,mixtures of strains comprising strains from multiple species andmicrobial types (i.e. yeasts, fungi and bacteria).

Those skilled in these arts will understand that cellulose is a polymerof β-D-glucose units that are linked together by 1-4 glycosidic bonds toform cellobiose residues that are the repeating units in cellulosefibrils which in turn, are intertwined to form cellulose fibers.Cellulose consists of ordered crystalline regions wherein the adjacentglycans are held together by hydrogen bonds randomly interspaced bydisordered amorphous regions of adjacent glycans. It is known thatamorphous regions of cellulose are more predisposed to hydrolysis bycellulytic enzyme activity, than are the crystalline regions.Accordingly, another exemplary embodiment of the present inventionrelates to optional methods and systems design for decrystallization ofthe cellulosic stream in the second module B prior to enzymatichydrolysis. The decrystallation step may be provided after, oralternatively, before adjustment of the viscosity of the cellulosicsolids stream received from the first module A. The decrystallation stepmay be provided after the cellulosic solids stream has beende-lignified. The cellulosic solids stream or alternatively, thede-lignified cellulosic pulp stream, may be decrystallized bycommingling the stream with a suitable decrystallation treatment andthen washing well the decrystallized stream with water before commencingwith enzymatic hydrolysis. Suitable decrystallization treatments areexemplified among others by phosphoric acid, trifloroacetic acid,monoethylamine, sodium hydroxide, ionic liquids comprising one or moreof methylimidazolium ions, pyridinium ions, pyrrolidinium ions,phosphonium ions, ammonium ions among others, and suitable combinationsthereof.

Another exemplary embodiment of the present invention relates toprocesses, systems and equipment configured for recovery and recyclingof hydrolytic enzymes provided in the second module B for separation ofcellulose pulps into one or more of monosaccharides, polysaccharides andoligosaccharides. According to one aspect, the hydrolytic enzymes arerecovered after saccharification during transfer of a monosaccharidesstream to a fermentation tank for conversion to a short-chain alcohol.An illustrative schematic flowchart generally outlining an enzymerecovery and recycling system loop cooperating with a hybridsaccharification and fermentation (HSF) system is shown in FIG. 8wherein a cellulosic pulp stream 500 recovered from a first module A, isdelivered to a saccharification tank 510 via a suitable pipeline 501. Asuitable preparation comprising fresh hydrolytic enzymes is delivered tothe saccharification tank 510 via line 522 from an enzyme holding tank520. The delivery of the enzyme preparation to the saccharification tank510 is controllable by valve 521 interposed line 522. After a suitabletime period of saccharification under suitable physical conditions(i.e., temperature and pressure), the hydrolysate comprising asolubilized carbohydrates stream and digested solids are removed fromsaccharification tank 510 via outlet line 526 with the aid of a pump 526and are transferred to a fermentation tank 530. Those skilled in thesearts will understand that a large portion of the hydrolytic enzymesadded to saccharification tank 510 will be attached to the spent solidsand the remainder will be distributed throughout the solubilizedcarbohydrates stream. The flow of the hydrolysate and digested solidsfrom the saccharification tank 510 to the fermentation tank iscontrollable and manipulable by diverter valves 528, 541. A portion ofthe flow of the hydrolysate and digested solids may be optionally bediverted to a solid/liquid separation unit 545 wherefrom the liquids aretransferred via line 546 to the fermentation tank 530 wherein they arecommingled with the liquid carbohydrates hydrolysate stream delivered byline 529. The settled solids are transferred via line 547 to an enzymerecovery tank 550 where the settled solids with enzymes attached theretoare reconditioned by commingling and intermixing with fresh cellulosicpulp stream 500 via pipeline 502. The reconditioned enzyme solids streamis transferred via pipeline 551 by pump 552 to a solid/liquid separationtank 560 from where the reconditioned enzymes are transferred viapipeline 561 back to the saccharification tank for hydrolysis of freshcellulosic pulp stream 500 via pipeline 501. Additional fresh enzymesmay be controllably added, if so desired, to the saccharification tank510 from the fresh enzyme holding tank 520 via line 522. A suitableinoculum comprising fermentative microorganism is controllably deliveredto the fermentation tank 530 via line 536 and valve 437 from a holdingtank 535. The fermentation beer comprising short-chain alcohols andspent solids is transferred from the fermentation tank 530 via line 538by pumping with pump 539 to a fermentation beer holding tank 580, fromwhere it is transferred for further processing and refining as describedelsewhere herein.

According to another aspect, an exemplary enzyme recovery and recyclingsystem may be configured to cooperate with an HSF system wherein thehydrolytic enzymes are recovered from beer egressing from a fermentationtank. An illustrative schematic flowchart generally outlining thisaspect is shown in FIG. 9 wherein a cellulosic pulp stream 500 recoveredfrom a first module A, is delivered to a saccharification tank 510 via asuitable pipeline 501. A suitable preparation comprising freshhydrolytic enzymes is delivered to the saccharification tank 510 vialine 522 from an enzyme holding tank 520. The delivery of the enzymepreparation to the saccharification tank is controllable by valve 521interposed line 522. After a suitable time period of saccharification inthe tank 510 under suitable physical conditions (i.e., temperature andpressure), the hydrolysate comprising a solubilized carbohydrates streamand digested solids is transferred from the saccharification tank 510 tothe fermentation tank via outlet line 526 with the aid of a pump 526. Asuitable inoculum comprising fermentative microorganism is controllablydelivered to the fermentation tank 530 via line 536 and valve 437 from aholding tank 535. After fermentation has proceeded for a suitable periodof time, the fermentation beer and spent solids are recovered from thefermentation tank 530 via outlet lines 610, 612 with the aid of a pump611 and are transferred to a fermentation beer storage tank 580. Thoseskilled in these arts will understand that in this HSF systemconfiguration, a large portion of the hydrolytic enzymes added tosaccharification tank 510 will be attached to the spent solids recoveredfrom the fermentation tank 530 and the remainder will be distributedthroughout the fermentation beer. The flow of the hydrolysate anddigested solids from the saccharification tank 510 to the fermentationtank is controllable and manipulable by diverter valves 613, 620. Aportion of the flow of the hydrolysate and digested solids may beoptionally be diverted to a solid/liquid separation unit 615 wherefromthe liquids are transferred via line 621 to the fermentation tank 530wherein they are commingled with the liquid carbohydrates hydrolysatestream delivered by line 612. The settled solids are transferred vialine 616 to an enzyme recovery tank 550 where the settled solids withenzymes attached thereto are reconditioned by commingling andintermixing with fresh cellulosic pulp stream 500 via pipeline 502. Thereconditioned enzyme solids stream is transferred via pipeline 551 bypump 552 to a solid/liquid separation tank 560 from where thereconditioned enzyme solids stream is transferred via pipeline 561 backto the saccharification tank for hydrolysis of fresh cellulosic pulpstream 500 via pipeline 501. Additional fresh enzymes may becontrollably added, if so desired, to the saccharification tank 510 fromthe fresh enzyme holding tank 520 via line 522. The separatedfermentation beer resulting from settling of the recondition enzymesolids stream in the solid/liquid separation tank 560 is transferred vialine 622 to the fermentation beer storage tank 580. The fermentationbeer is subsequently transferred from the fermentation beer holding tank580 for further processing and refining as described elsewhere herein.

According to another aspect, the hydrolytic enzymes are recoverable frombeer egressing from a tank containing therein simultaneoussaccharification and fermentation (SSF) processes. An illustrativeschematic flowchart generally outlining this aspect is shown in FIG. 10wherein a cellulosic pulp stream 500 recovered from a first module A, isdelivered to a saccharification/fermentation tank 700 via pipeline 501.A suitable preparation comprising fresh hydrolytic enzymes is deliveredto the saccharification/fermentation tank 700 via line 522 from anenzyme holding tank 520. The delivery of the enzyme preparation to thesaccharification/fermentation tank 700 is controllable by valve 521interposed line 522. A suitable inoculum comprising fermentativemicroorganisms is controllably delivered to thesaccharification/fermentation tank 700 via line 536 and valve 437 from aholding tank 535. After a suitable time period of saccharification andfermentation under suitable physical conditions (i.e., temperature andpressure), the fermentation beer and spent solids are recovered from thesaccharification/fermentation tank 700 via outlet line 701 with the aidof a pump 702 and are transferred to a fermentation beer storage tank580. Those skilled in these arts will understand that in this SSF systemconfiguration, a large portion of the hydrolytic enzymes added tosaccharification/fermentation tank 700 will be attached to the recoveredspent solids and the remainder will be distributed throughout thefermentation beer.

The flow of the hydrolysate and digested solids from thesaccharification tank 510 to the fermentation tank is controllable andmanipulable by diverter valves 705, 706. A portion of the flow of thehydrolysate and digested solids may be optionally be diverted to asolid/liquid separation unit 710 wherefrom the liquids are transferredvia line 711 to the fermentation tank 530 wherein they are commingledwith the liquid carbohydrates hydrolysate stream delivered by line 704.The settled solids are transferred via line 712 to a solid/liquidseparation tank 560 from where the reconditioned enzyme solids stream isallowed to further settle after which the settled enzyme solids streamis transferred via pipeline 561 back to the saccharification tank forhydrolysis of fresh cellulosic pulp stream 500 via pipeline 501.Additional fresh enzymes may be controllably added, if so desired, tothe saccharification tank 510 from the fresh enzyme holding tank 520 vialine 522. Additional fresh fermentative microorganisms is controllablydelivered to the saccharification/fermentation tank 700 via line 536 andvalve 437 from the holding tank 535. The separated fermentation beerresulting from additional settling of the enzyme solids stream in thesolid/liquid separation tank 560 is transferred via line 713 to thefermentation beer storage tank 580. The fermentation beer issubsequently transferred from the fermentation beer holding tank 580 forfurther processing and refining as described elsewhere herein.

The systems, methods and processes for fractionating lignocellulosicfeedstocks into component parts which are then subsequently separatedare described in more detail in the following examples with a selectedhardwood and a selected softwood species. The following examples areintended to be exemplary of the invention and are not intended to belimiting.

Example 1

Representative samples of whole logs of British Columbian aspen (Populustremula) (˜125 years old) were collected. After harvesting, logs weredebarked, split, chipped, and milled to a chip size of approximately ≦10mm×10 mm×3 mm. Chips were stored at room temperature (moisture contentat equilibrium was ˜10%). The aspen chips were organosolv-pretreated inaqueous ethanol (50% w/w ethanol) with no addition of exogenous acid orbase, in a 2-L Parr® reactor (Parr is a registered trademark of the ParrInstrument Company, Moline, Ill., USA). Duplicate 200 g (ODW) samples ofthe aspen chips, designated as ASP1, were cooked at 195° C. for 60 minThe liquor:wood ratio was 5:1 weight-based. After cooking, the reactorwas cooled to room temperature. Solids and the spent liquor were thenseparated by filtration. Solids were intensively washed with a hotethanol solution (70° C.) followed by a tap water wash step. Themoisture content of the washed pulp was reduced to about 40% with thehelp of a hydraulic press (alternatively a screw press can be used). Thewashed pulp was homogenized and stored in a fridge at 4° C. The chemicalcomposition (hexose, pentose, lignin content) of washed and unwashedpulps was determined according to a modified Klason lignin methodderived from the Technical Association of Pulp and Paper Industry(TAPPI) standard method T222 om-88 (TAPPI methods in CD-ROM, 2004, TAPPIPress). Liquids were analyzed for carbohydrate degradation products(furfural, 5-hydromethylfurfural), organic acids, and oligo- andmonosaccharides according to standard procedures established by theNational Renewable Energy Laboratory (NREL, Golden, Colo., USA). Theresulting data were used to calculate overall lignin and carbohydraterecoveries and process mass balance. The carbohydrate composition andoverall carbohydrate recoveries from the raw and pretreated aspen chipsare shown in Table 1. 222.2 g (oven-dried weight, odw) of ASP1 pulp wererecovered after batch organosolv processing of 400 g of aspen wood chips(55.6% pulp yield) containing mainly fermentable-into-ethanolcarbohydrates. Pentoses and hexoses were partially degraded resulting in0.71 g Kg⁻¹ of furfural and 0.06 g Kg⁻¹ of 5-HMF, respectively. Thedifferent classes of lignins recovered from the pulp and liquors areshown in Table 2.

TABLE 1 Carbohydrate content of raw and pretreated aspen chips (ASP1pretreatment conditions) and overall carbohydrate recovery RawPretreated Feedstock Raw Feedstock Output Carbohydrates Recovery chipsInput Pulp Liquor Total Soluble Insoluble Total Component (%) (g) (g)(g) (g) (%) (%) (%) Arabinan 0.44 1.75 0.04 0.17 0.21 9.69 2.53 12.23Galactan 0.43 1.71 0.16 0.26 0.42 15.16 9.07 24.23 Glucan 48.76 195.03185.40 0.32 185.72 0.16 95.06 95.23 Xylan 16.44 65.75 17.60 8.70 26.3013.23 26.77 40.00 Mannan 1.48 5.92 4.62 0 4.62 0 78.02 78.02 Total:67.55 270.16 207.82 9.45 217.27

TABLE 2 Lignin input in raw aspen chips and lignin fractions recoveredafter organosolv pretreatment (ASP1 pretreatment conditions) RawPretreated Pretreated Feed- Feedstock Feedstock stock Solids LiquidsInput Output Output Component (g) (odw, g) (odw, g) Raw lignin (AIL +ASL) 91.35 — — Self-precipitated lignin (HMW) — —  9.60 Precipitatedlignin* (MMW) — — 32.12 Very low molecular wt. (VLMW) — — 11.72 ligninResidual lignin (VHMW) — 11.33 — Total: 91.35 11.33 53.44 *recoveredfrom the liquor by precipitation with water; AIL—acid-insoluble lignin;ASL—acid-soluble lignin

The potential of the washed pulp for production of ethanol was evaluatedin 100-mL Erlenmeyer flasks. The pH of the washed pulp was firstadjusted with a water ammonia solution to pH 5.50, then placed intoErlenmeyer flasks and resuspended in distilled water to a total reactionweight of 100 g (including the yeast and enzyme weight, the finalreaction volume was ˜100 mL) and a final solids concentration of 16%(w/w). The ethanol production process was run according to asimultaneous saccharification and fermentation scheme (SSF) using afungal cellulase preparation containing all of the enzyme activitiesrequired to depolymerize cellulose at 15 FPU g⁻¹ glucan supplementedwith a fungal beta-glucosidase preparation (30 CBU g⁻¹ glucan) and aethanologenic yeast, Saccharomyces cerevisiae strain Y-1528 (availablefrom the Agricultural Research Service, United States Department ofAgriculture, Peoria, Ill., USA) at 10 g/L dry cell wt. capable offermenting all hexoses. The mixture was incubated at 36° C., 150 rpm for48 h. Samples were taken for ethanol analysis by gas chromatography at0, 24, 36, and 48 h. The ethanol yield obtained was 39.40% theoreticalethanol yield based on initial hexose input. The final ethanol beerconcentration was 3.26% (w/w) (FIGS. 11 a and 11 b).

Example 2

Duplicate 200-g samples of the wood chips prepared in Example 1,designated as ASP2, were used for this study. The aspen chips wereorganosolv-pretreated in aqueous ethanol (50% w/w ethanol) with noaddition of exogenous acid or base, in a 2-L Parr® reactor. Duplicate200 g (ODW) samples of aspen chips were cooked at 195° C. for 90 min.The liquor:wood ratio was 5:1 (w:w). After cooking, the reactor wascooled to room temperature. Solids and liquids were then separated byfiltration. Solids were intensively washed with a hot ethanol solution(70° C.) followed by a tap water wash step. The moisture content of thewashed pulp was reduced to about 40% with the help of a hydraulic press(alternatively a screw press can be used). The washed pulp washomogenized and stored in a fridge at 4° C. The chemical composition(hexose, pentose, lignin content) of raw chips, washed, and unwashedpulps was determined according to a modified Klason lignin methodderived from the Technical Association of Pulp and Paper Industry(TAPPI) standard method. T222 om-88 (TAPPI methods in CD-ROM, 2004,TAPPI Press). Liquids were analyzed for carbohydrate degradationproducts (furfural, 5-hydromethylfurfural), acids, and oligo- andmonosaccharides according to standard procedures established by theNational Renewable Energy Laboratory (NREL, Golden, Colo., USA). Theresulting data were used to calculate overall carbohydrate and ligninrecoveries and process mass balance. The carbohydrate composition andoverall carbohydrate recoveries from the raw and pretreated aspen chipsare shown in Table 3. 230.2 g (odw) of pulp were recovered after batchorganosolv processing of 400 g of aspen wood chips (57.6% pulp yield),and comprised mainly fermentable-into-ethanol carbohydrates. Pentosesand hexoses were partially degraded resulting in 0.53 g Kg⁻¹ of furfuraland 0.05 g Kg⁻¹ of 5-HMF, respectively. The lignin content in the rawaspen chips and overall lignin recovery after pretreatment are shown inTable 4.

TABLE 3 Carbohydrate content of raw and pretreated aspen chips (ASP2pretreatment conditions) and overall carbohydrate recovery RawPretreated Feedstock Raw Feedstock Output Carbohydrates Recovery chipsInput Pulp Liquor Total Soluble Insoluble Total Component (%) (g) (g)(g) (g) (%) (%) (%) Arabinan 0.44 1.75 0 0.22 0.22 12.54 0.00 12.54Galactan 0.43 1.71 0 0.21 0.21 12.25 0.00 12.25 Glucan 48.76 195.03194.50 0.37 194.87 0.19 99.73 99.92 Xylan 16.44 65.75 14.80 6.76 21.5610.28 22.51 32.79 Mannan 1.48 5.92 4.07 0.34 4.41 5.74 68.78 74.52Total: 67.55 270.16 213.37 7.9 221.27

TABLE 4 Lignin input in raw aspen chips and lignin fractions recoveredafter organosolv pretreatment (ASP2 pretreatment conditions) RawPretreated Pretreated Feed- Feedstock Feedstock stock Solids LiquidsInput Output Output Component (g) (odw, g) (odw, g) Raw lignin (AIL +ASL) 91.35 — — Self-precipitated lignin (HMW) — —  9.14 Precipitatedlignin* (MMW) — — 43.09 Very low molecular wt. (VLMW) — — 12.60 ligninResidual lignin (VHMW) — 7.32 — Total: 91.35 7.32 64.83 *recovered fromthe liquor by precipitation with water; AIL—acid-insoluble lignin;ASL—acid-soluble lignin

Production of ethanol from the washed pulp was evaluated in 100-mLErlenmeyer flasks. The experiments in Erlenmeyer flasks were run asfollows. The pH of the washed pulp was adjusted with a water ammoniasolution to pH 5.50, then placed into Erlenmeyer flasks and resuspendedin distilled water to a total reaction weight of 100 g (including theyeast and enzyme weight, the total reaction volume was ˜100 mL) and afinal solids concentration of 16% (w/w). The ethanol process was runaccording to a SSF using a fungal cellulase preparation containing allof the enzyme activities required to depolymerize cellulose at 15 FPUg⁻¹ glucan supplemented with a fungal beta-glucosidase preparation (30CBU g⁻¹ glucan) and an ethanologenic yeast, Saccharomyces cerevisiaestrain Y-1528 at 10 g/L dry cell wt. capable of fermenting all hexoses.The mixture was incubated at 36° C., 150 rpm for 48 h. Samples weretaken for ethanol analysis by gas chromatography at 0, 24, 36, and 48 h.The ethanol yield obtained was 79.30% theoretical ethanol yield based oninitial hexose input. The final ethanol beer concentration was 6.33%(w/w) (FIGS. 11 a and 11 b).

Example 3

Duplicate 200-g samples of the wood chips prepared in Example 1,designated as ASP3, were used for this study. The aspen chips wereorganosolv-pretreated in aqueous ethanol (50% w/w ethanol) with noaddition of exogenous acid or base, in a 2-L Parr® reactor. Theduplicate samples of aspen chips were cooked in duplicate at 195° C. for120 min. The liquor:wood ratio was 5:1 (w:w). After cooking, the reactorwas cooled to room temperature. Solids and liquids were then separatedby filtration. Solids were intensively washed with a hot ethanolsolution (70° C.) followed by a tap water wash step. The moisturecontent of the washed pulp was reduced to about 40% with the help of ahydraulic press (alternatively a screw press can be used). The washedpulp was homogenized and stored in a fridge at 4° C. The chemicalcomposition (hexose, pentose, lignin content) of raw chips, washed, andunwashed pulps was determined according to a modified Klason ligninmethod derived from the Technical Association of Pulp and Paper Industry(TAPPI) standard method T222 om-88. Liquids were analyzed forcarbohydrate degradation products (furfural, 5-hydromethylfurfural),acids, and oligo- and monosaccharides according to standard proceduresestablished by the National Renewable Energy Laboratory. The resultingdata were used to calculate overall carbohydrate and lignin recoveriesand process mass balance. The carbohydrate composition and overallcarbohydrate recoveries from the raw and pretreated aspen chips areshown in Table 5. 219.9 g (odw) of pulp were recovered after batchorganosolv processing of 400 g of aspen wood chips (54.98% pulp yield)containing mainly fermentable-into-ethanol carbohydrates. Pentoses andhexoses were partially degraded resulting in 0.92 g Kg⁻¹ of furfural and0.08 g Kg⁻¹ of 5-HMF, respectively. The lignin contents in raw aspenchips and overall lignin recovery after pretreatment are shown in Table6.

Production of ethanol from the washed pulp was evaluated in 100-mLErlenmeyer flasks. The experiments in Erlenmeyer flasks were run asfollows. The pH of the washed pulp was adjusted with a water ammoniasolution to pH 5.50, placed into Erlenmeyer flasks and resuspended indistilled water to a total reaction weight of 100 g (including the yeastand enzyme weight, the total reaction volume was ˜100 mL) and a finalsolids concentration of 16% (w/w). The ethanol process was run accordingto a SSF scheme using a fungal cellulase preparation containing all ofthe enzyme activities required to depolymerize cellulose at 15 FPU g⁻¹glucan supplemented with a fungal beta-glucosidase preparation (30 CBUg⁻¹ glucan) and an ethanologenic yeast, Saccharomyces cerevisiae strainY-1528 at 10 g/L dry cell wt. capable of fermenting all hexoses. Themixture was incubated at 36° C., 150 rpm for 48 h. Samples were takenfor ethanol analysis by gas chromatography at 0, 24, 36, and 48 h. Theethanol yield obtained was 79.00% theoretical ethanol yield based oninitial hexose input. The final ethanol beer concentration was 6.60%(w/w) (FIGS. 11 a and 11 b).

TABLE 5 Carbohydrate content of raw and pretreated aspen chips (ASP3pretreatment conditions) and overall carbohydrate recovery RawPretreated Feedstock Raw Feedstock Output Carbohydrates Recovery chipsInput Pulp Liquor Total Soluble Insoluble Total Component (%) (g) (g)(g) (g) (%) (%) (%) Arabinan 0.44 1.75 0 0.10 0.10 5.70 0 5.70 Galactan0.43 1.71 0 0.15 0.15 8.75 0 8.75 Glucan 48.76 195.03 186.63 0.33 186.960.17 95.69 95.86 Xylan 16.44 65.75 12.56 4.03 16.59 6.13 19.10 25.23Mannan 1.48 5.92 3.50 0.30 3.80 5.06 59.02 64.08 Total: 67.55 270.16202.69 4.91 207.6

TABLE 6 Lignin input in raw aspen chips and lignin fractions recoveredafter organosolv pretreatment (ASP3 pretreatment conditions) RawPretreated Pretreated Feed- Feedstock Feedstock stock Solids LiquidsInput Output Output Component (g) (odw, g) (odw, g) Raw lignin (AIL +ASL) 91.35 — — Self-precipitated lignin (HMW) — —  0.16 Precipitatedlignin* (MMW) — — 40.70 Very low molecular wt. (VLMW) — — 11.46 ligninResidual lignin (VHMW) — 6.47 — Total: 91.35 6.47 52.32 *recovered fromthe liquor by precipitation with water; AIL—acid-insoluble lignin;ASL—acid-soluble lignin

Example 4

Representative samples of British Columbian beetle-killed lodgepole pine(Pinus contorta) sapwood (˜120 years old) were collected. Afterharvesting, logs were debarked, split, chipped, and milled to a chipsize of approximately ≦10 mm×10 mm×3 mm Chips were stored at roomtemperature (moisture content at equilibrium was ˜10%). Duplicate 200-gsamples of these wood chips, designated as BKLLP1, were used for thisstudy. The chips were organosolv-pretreated in aqueous ethanol (50% w/wethanol) with addition of 1.10% (w/w) sulfuric acid, in a 2-L Parr®reactor. The chips were cooked in duplicate at 170° C. for 60 min. Theliquor:wood ratio was 5:1 (w:w). After cooking, the reactor was cooledto room temperature. Solids and liquids were then separated byfiltration. Solids were intensively washed with a hot ethanol solution(70° C.) followed by a tap water wash step. The moisture content of thewashed pulp was reduced to about 40% with the help of a hydraulic press(alternatively a screw press can be used). The washed pulp washomogenized and stored in a fridge at 4° C. The chemical composition(hexose, pentose, lignin content) of raw chips, washed, and unwashedpulps was determined according to a modified Klason lignin methodderived from the Technical Association of Pulp and Paper Industry(TAPPI) standard method T222 om-88. Liquids were analyzed forcarbohydrate degradation products (furfural, 5-hydromethylfurfural),acids, and oligo- and monosaccharides according to standard proceduresestablished by the National Renewable Energy Laboratory. The obtaineddata were used to calculate overall carbohydrate and lignin recoveriesand process mass balance. The carbohydrate composition and the overallcarbohydrate recoveries from the raw and pretreated beetle-killedlodgepole pine chips are shown in Table 7. 177.2 g (odw) of pulp wererecovered after batch organosolv processing of 400 g of wood chips(44.30% pulp yield) containing mainly fermentable-into-ethanolcarbohydrates. Pentoses and hexoses were partially degraded resulting in0.72 g Kg⁻¹ of furfural and 1.78 g Kg⁻¹ of 5-HMF, respectively. Thelignin content in raw beetle-killed lodgepole pine chips and overalllignin recovery after pretreatment are shown in Table 8.

TABLE 7 Carbohydrate content of raw and pretreated beetle-killedlodgepole pine chips (BKLLP1 pretreatment conditions) and overallcarbohydrate recovery Raw Pretreated Feedstock Raw Feedstock OutputCarbohydrates Recovery chips Input Pulp Liquor Total Soluble InsolubleTotal Component (%) (g) (g) (g) (g) (%) (%) (%) Arabinan 1.76 7.03 0.050.77 0.82 10.96 0.76 11.72 Galactan 2.01 8.05 0.35 1.25 1.60 15.52 4.4019.92 Glucan 45.55 182.22 150.44 4.37 154.81 2.40 82.56 84.96 Xylan 7.2228.90 3.58 1.64 5.22 5.68 12.39 18.07 Mannan 11.07 44.29 6.06 0.00 6.060.00 13.68 13.68 Total: 67.61 270.49 160.48 8.03 168.51

TABLE 8 Lignin input in raw beetle-killed lodgepole pine chips andlignin fractions recovered after organosolv pretreatment (BKLLP1pretreatment conditions) Raw Pretreated Pretreated Feedstock FeedstockFeedstock Input Solids Output Liquids Output Component (g) (odw, g)(odw, g) Raw lignin (AIL + ASL) 106.85 — — Self-precipitated lignin(HMW) — —  0.17 Precipitated lignin* (MMW) — — 28.10 Very low molecularwt. lignin (VLMW) — — 13.47 Residual lignin (VHMW) — 15.29 — Total:106.85 15.29 41.74 *recovered from the liquor by precipitation withwater; AIL—acid-insoluble lignin; ASL—acid-soluble lignin

Production of ethanol from the washed pulp was evaluated in 100-mLErlenmeyer flasks. The experiments in Erlenmeyer flasks were run asfollows. The pH of the washed pulp was adjusted with a water ammoniasolution to pH 5.50, placed into Erlenmeyer flasks and resuspended indistilled water to a total reaction weight of 100 g (including the yeastand enzyme weight, the total reaction volume was ˜100 mL) and a finalsolids concentration of 16% (w/w). The ethanol process was run accordingto a simultaneous saccharification and fermentation scheme (SSF) using afungal cellulase preparation containing all of the enzyme activitiesrequired to depolymerize cellulose at 15 FPU g⁻¹ glucan supplementedwith a fungal beta-glucosidase preparation (30 CBU g⁻¹ glucan) togetherwith an ethanologenic yeast, Saccharomyces cerevisiae strain Y-1528 at10 g/L dry cell wt. capable of fermenting all hexoses. The mixture wasincubated at 36° C., 150 rpm for 48 h. Samples were taken for ethanolanalysis by gas chromatography at 0, 24, 36, and 48 h. The ethanol yieldobtained was 60.50% theoretical ethanol yield based on initial hexoseinput. The final ethanol beer concentration was 7.18% (w/w) (FIGS. 12 aand 12 b).

Example 5

Duplicate 200-g samples British Columbian beetle-killed lodgepole pine(Pinus contorta), designated as BKLLP2, of the chips prepared for thestudy described in the Example 4, were organosolv-pretreated in aqueousethanol (50% w/w ethanol) with addition of 1.10% (w/w) sulphuric acid,in a 2-L Parr® reactor. Duplicate 200-g (ODW) samples of chips werecooked at 175° C. for 60 min. The liquor:wood ratio was 5:1 (w:w). Aftercooking, the reactor was cooled to room temperature. Solids and liquidswere then separated by filtration. Solids were intensively washed with ahot ethanol solution (70° C.) followed by a tap water wash step. Themoisture content of the washed pulp was reduced to about 40% with thehelp of a hydraulic press (alternatively a screw press can be used). Thewashed pulp was homogenized and stored in a fridge at 4° C. The chemicalcomposition (hexose, pentose, lignin content) of raw chips, washed, andunwashed pulps was determined according to a modified Klason ligninmethod derived from the Technical Association of Pulp and Paper Industry(TAPPI) standard method T222 om-88. Liquids were analyzed forcarbohydrate degradation products (furfural, 5-hydromethylfurfural),acids, and oligo- and monosaccharides according to standard proceduresestablished by the National Renewable Energy Laboratory. The resultingdata were used to calculate overall carbohydrate and lignin recoveriesand process mass balance. The carbohydrate composition and the overallcarbohydrate recoveries from the raw and pretreated beetle-killedlodgepole pine chips are shown in Table 9. 144.4 g (odw) of pulp wererecovered after batch organosolv processing of 400 g of wood chips(36.10% pulp yield) containing mainly fermentable-into-ethanolcarbohydrates. Pentoses and hexoses were partially degraded resulting in0.92 g Kg⁻¹ of furfural and 1.87 g Kg⁻¹ of 5-HMF, respectively. Thelignin content in raw beetle-killed lodgepole pine chips and overalllignin recovery after pretreatment are shown in Table 10.

TABLE 9 Carbohydrate content of raw and pretreated beetle-killedlodgepole pine chips (BKLLP2 pretreatment conditions) and overallcarbohydrate recovery Raw Pretreated Feedstock Raw Feedstock OutputCarbohydrates Recovery chips Input Pulp Liquor Total Soluble InsolubleTotal Component (%) (g) (g) (g) (g) (%) (%) (%) Arabinan 1.76 7.03 0.040.39 0.43 5.55 0.62 6.17 Galactan 2.01 8.05 0.03 0.79 0.82 9.81 0.3610.17 Glucan 45.55 182.22 134.08 5.28 139.36 2.90 73.58 76.48 Xylan 7.2228.90 1.59 0.65 2.24 2.25 5.50 7.75 Mannan 11.07 44.29 2.30 0 2.30 05.18 5.18 Total: 67.61 270.49 138.04 7.11 145.15

TABLE 10 Lignin input in raw beetle-killed lodgepole pine chips andlignin fractions recovered after organosolv pretreatment (BKLLP2pretreatment conditions) Raw Pretreated Pretreated Feed- FeedstockFeedstock stock Solids Liquids Input Output Output Component (g) (odw,g) (odw, g) Raw lignin (AIL + ASL) 106.85 — — Self-precipitated lignin(HMW) — —  0.13 Precipitated lignin* (MMW) — — 33.01 Very low molecularwt. (VLMW) — — 11.88 lignin Residual lignin (VHMW) — 7.15 — Total:106.85 7.15 45.02 *recovered from the liquor by precipitation withwater; AIL—acid-insoluble lignin; ASL—acid-soluble lignin

Production of ethanol from the washed pulp was evaluated in 100-mLErlenmeyer flasks. The experiments were run as follows. The pH of thewashed pulp was adjusted with a water ammonia solution to pH 5.50,placed into Erlenmeyer flasks and resuspended in distilled water to atotal reaction weight of 100 g (including the yeast and enzyme weight,the total reaction volume was ˜100 ml) and a final solids concentrationof 16% (w/w). The ethanol process was run according to a simultaneoussaccharification and fermentation scheme (SSF) using a fungal cellulasepreparation containing all of the enzyme activities required todepolymerize cellulose at 15 FPU g⁻¹ glucan supplemented with a fungalbeta-glucosidase preparation (30 CBU g⁻¹ glucan) and an ethanologenicyeast, Saccharomyces cerevisiae strain Y-1528 at 10 g/L dry cell wt.capable of fermenting all hexoses. The mixture was incubated at 36° C.,150 rpm for 48 h. Samples were taken for ethanol analysis by gaschromatography at 0, 24, 36, and 48 h. The ethanol yield obtained was53.10% theoretical ethanol yield based on initial hexose input. Thefinal ethanol beer concentration was 7.74% (w/w) (FIGS. 12 a and 12 b).

Example 6

Duplicate 200-g samples British Columbian beetle-killed lodgepole pine(Pinus contorta), designated as BKLLP3, chips prepared for the studydescribed in the Example 4, were organosolv-pretreated in aqueousethanol (50% w/w ethanol) with addition of 1.10% (w/w) sulphuric acid,in a 2-L Parr® reactor chips were cooked in duplicate at 180° C. for 60min. The liquor:wood ratio was 5:1 (w:w). After cooking, the reactor wascooled to room temperature. Solids and liquids were then separated byfiltration. Solids were intensively washed with a hot ethanol solution(70° C.) followed by a tap water wash step. The moisture content of thewashed pulp was reduced to about 40% with the help of a hydraulic press(alternatively a screw press can be used). The washed pulp washomogenized and stored in a fridge at 4° C. The chemical composition(hexose, pentose, lignin content) of raw chips, washed, and unwashedpulps was determined according to a modified Klason lignin methodderived from the Technical Association of Pulp and Paper Industry(TAPPI) standard method T222 om-88. Liquids were analyzed forcarbohydrate degradation products (furfural, 5-hydromethylfurfural),acids, and oligo- and monosaccharides according to standard proceduresestablished by the National Renewable Energy Laboratory. The resultingdata were used to calculate overall carbohydrate and lignin recoveriesand process mass balance. The carbohydrate composition and the overallcarbohydrate recoveries from the raw and pretreated beetle-killedlodgepole pine chips are shown in Table 11. 120.7 g (odw) of pulp wasrecovered after batch organosolv processing of 400 g of wood chips(30.18% pulp yield) containing mainly fermentable into ethanolcarbohydrates. Pentoses and hexoses were partially degraded resulting in1.47 g Kg⁻¹ of furfural and 2.17 g Kg⁻¹ of 5-HMF, respectively. Thelignin content in raw aspen chips and overall lignin recovery afterpretreatment are shown in Table 12.

TABLE 11 Carbohydrate content of raw and pretreated beetle-killedlodgepole pine chips (BKLLP3 pretreatment conditions) and overallcarbohydrate recovery Raw Pretreated Feedstock Raw Feedstock OutputCarbohydrates Recovery chips Input Pulp Liquor Total Soluble InsolubleTotal Component (%) (g) (g) (g) (g) (%) (%) (%) Arabinan 1.76 7.03 0.040.22 0.26 3.13 0.52 3.65 Galactan 2.01 8.05 0.33 0.61 0.94 7.57 4.0511.62 Glucan 45.55 182.22 102.34 6.15 108.49 3.38 56.16 59.54 Xylan 7.2228.90 2.34 0.41 2.75 1.42 8.10 9.52 Mannan 11.07 44.29 3.86 2.07 5.934.67 8.72 13.39 Total: 67.61 270.49 108.91 9.46 118.37

TABLE 12 Lignin input in raw beetle-killed lodgepole pine chips andlignin fractions recovered after organosolv pretreatment (BKLLP3pretreatment conditions) Raw Pretreated Pretreated Feed- FeedstockFeedstock stock Solids Liquids Input Output Output Component (g) (odw,g) (odw, g) Raw lignin (AIL + ASL) 106.85 — — Self-precipitated lignin(HMW) — —  0.26 Precipitated lignin* (MMW) — — 33.64 Very low molecularwt. (VLMW) — — 15.33 lignin Residual lignin (VHMW) — 9.11 — Total:106.85 9.11 49.23 *recovered from the liquor by precipitation withwater; AIL—acid-insoluble lignin; ASL—acid-soluble lignin

Production of ethanol from the washed pulp was evaluated in 100-mLErlenmeyer flasks. The experiments in Erlenmeyer flasks were run asfollows. The pH of the washed pulp was adjusted with a water ammoniasolution to pH 5.50, placed into Erlenmeyer flasks and resuspended indistilled water to a total reaction weight of 100 g (including the yeastand enzyme weight, the total reaction volume was ˜100 mL) and a finalsolids concentration of 16% (w/w). The ethanol process was run accordingto a SSF scheme using a fungal cellulase preparation containing all ofthe enzyme activities required to depolymerize cellulose at 15 FPU g⁻¹glucan supplemented with a fungal beta-glucosidase preparation (30 CBUg⁻¹ glucan) and an ethanologenic yeast, Saccharomyces cerevisiae strainY-1528 at 10 g/L dry cell wt. capable of fermenting all hexoses. Themixture was incubated at 36° C., 150 rpm for 48 h. Samples were takenfor ethanol analysis by gas chromatography at 0, 24, 36, and 48 h. Theethanol yield obtained was 44.60% theoretical ethanol yield based oninitial hexose input. The final ethanol beer concentration was 7.79%(w/w) (FIGS. 12 a and 12 b).

Example 7

Representative samples of wheat straw (Triticum sp.) from EasternWashington, USA were collected. Wheat straw was cut into ˜5-cm chips andstored at room temperature (moisture content at equilibrium was ˜10%).The straw was organosols-pretreated in aqueous ethanol (50% w/w ethanol)with no addition of exogenous acid or base, in a 2-L Parr® reactor.Duplicate 100-g (ODW) samples of wheat straw, designated as WS-1, werecooked in duplicate at 195° C. for 90 min. The liquor:raw material ratiowas 10:1 (w/w). After cooking, the reactor was cooled to roomtemperature. Solids and the spent liquor were then separated byfiltration. Solids were intensively washed with a hot ethanol solution(70° C.) followed by a tap water wash step. The moisture content of thewashed pulp was reduced to about 50% with the help of a hydraulic press(alternatively a screw press can be used). The washed pulp washomogenized and stored in a fridge at 4° C. The chemical compositions(hexose, pentose, lignin content) of washed and unwashed pulps weredetermined according to a modified Klason lignin method derived from theTechnical Association of Pulp and Paper Industry (TAPPI) standard methodT222 om-88. Liquids were analyzed for carbohydrate degradation products(furfural, 5-hydromethylfurfural), acids, and oligo- and monosaccharidesaccording to standard procedures established by the National RenewableEnergy Laboratory. The resulting data were used to calculate overallcarbohydrate and lignin recoveries and process mass balance. Thecarbohydrate composition and the overall carbohydrate recoveries fromthe raw and pretreated wheat straw are shown in Table 13. 46.8 g(oven-dried weight, odw) of WS-1 pulp was recovered after batchorganosolv processing of 100 g of wheat straw (46.8% pulp yield)containing mainly fermentable-into-ethanol carbohydrates. Pentoses andhexoses were partially degraded resulting in 0.39 g Kg⁻¹ of furfural and0.03 g Kg⁻¹ of 5-HMF, respectively. The lignin content in raw wheatstraw and overall lignin recovery after pretreatment are shown in Table14.

TABLE 13 Carbohydrate content of raw and pretreated wheat straw chips(WS-1 pretreatment conditions) and overall carbohydrate recovery RawPretreated Feedstock Raw Feedstock Output Carbohydrates Recovery chipsInput Pulp Liquor Total Soluble Insoluble Total Component (%) (g) (g)(g) (g) (%) (%) (%) Arabinan 3.85 3.85 0.00 0.17 0.17 4.39 0.00 4.39Galactan 1.16 1.16 0.00 0.19 0.19 16.72 0.00 16.72 Glucan 54.92 54.9235.47 0.00 35.47 0.00 64.58 64.58 Xylan 27.83 27.83 3.36 2.68 6.03 9.6212.06 21.67 Mannan 0.53 0.53 0.00 0.08 0.08 15.78 0.00 15.78 Total:88.30 88.30 38.83 3.12 41.94

TABLE 14 Lignin input in raw wheat straw chips and lignin fractionsrecovered after organosolv pretreatment (WS-1 pretreatment conditions)Raw Pretreated Pretreated Feed- Feedstock Feedstock stock Solids LiquidsInput Output Output Component (g) (odw, g) (odw, g) Raw lignin (AIL +ASL) 17.44 — — Self-precipitated lignin (HMW) — — 1.7 Precipitatedlignin* (MMW) — — 8.4 Very low molecular wt. (VLMW) — — — ligninResidual lignin (VHMW) — 4.31 — Total: 17.44 4.31 10.1  *recovered fromthe liquor by precipitation with water; AIL—acid-insoluble lignin;ASL—acid-soluble lignin

The potential of the produced washed wheat straw pulp for production ofethanol was evaluated in 100-mL Erlenmeyer flasks. The experiments inErlenmeyer flasks were run as follows. The pH of the washed pulp wasadjusted with a water ammonia solution to pH 5.50, placed intoErlenmeyer flasks and resuspended in distilled water to a total reactionweight of 100 g (including the yeast and enzyme weight, the finalreaction volume was ˜100 mL) and a final solids concentration of 16%(w/w). The ethanol process was run according to a SSF scheme using afungal cellulase preparation containing all of the enzyme activitiesrequired to depolymerize cellulose at 15 EPU g⁻¹ glucan supplementedwith a fungal beta-glucosidase preparation (30 CBU g⁻¹ glucan) and anethanologenic yeast, Saccharomyces cerevisiae strain Y-1528 at 10 g/Ldry cell wt. capable of fermenting all hexoses. The mixture wasincubated at 36° C., 150 rpm for 48 h. Samples were taken for ethanolanalysis by gas chromatography at 0, 24, 36, and 48 h. The ethanol yieldobtained was 88.86% theoretical ethanol yield based on initial hexoseinput. The final ethanol beer concentration was 6.14% (w/w) (FIGS. 13 aand 13 b).

Example 8

Representative samples of switchgrass (Panicum virgatum) from Tennessee,USA were collected. The switchgrass samples were cut to a particle sizeof approximately 5 cm and stored at room temperature (moisture contentat equilibrium was ˜10%). The switchgrass chips wereorganosols-pretreated in aqueous ethanol (50% w/w ethanol) with noaddition of exogenous acid or base, in a 2-L Parr® reactor. Duplicate100-g (odw) switchgrass samples designated as SWG-1, were cooked at 195°C. for 90 min. The liquor:raw material ratio was 10:1 (w/w). Aftercooking, the reactor was cooled to room temperature. Solids and thespent liquor were then separated by filtration. Solids were intensivelywashed with a hot ethanol solution (70° C.) followed by a tap water washstep. The moisture content of the washed pulp was reduced to about 50%with the help of a hydraulic press (alternatively a screw press can beused). The washed pulp was homogenized and stored in a fridge at 4° C.The chemical composition (hexose, pentose, lignin content) of washed andunwashed pulps was determined according to a modified Klason ligninmethod derived from the Technical Association of Pulp and Paper Industry(TAPPI) standard method T222 om-88. Liquids were analyzed forcarbohydrate degradation products (furfural, 5-hydromethylfurfural),acids, and oligo- and monosaccharides according to standard proceduresestablished by the National Renewable Energy Laboratory. The resultingdata were used to calculate overall carbohydrate and lignin recoveriesand process mass balance. The carbohydrate composition and the overallcarbohydrate recoveries from the raw and pretreated switchgrass areillustrated in Table 15. 45.2 g (oven-dried weight, odw) of SWG-1 pulpwas recovered after batch organosolv processing of 100 g of switchgrass(45.2% pulp yield) containing mainly fermentable-into-ethanolcarbohydrates. Pentoses and hexoses were partially degraded resulting in0.917 g Kg⁻¹ of furfural and 0.21 g Kg⁻¹ of 5-HMF, respectively. Thelignin content in raw switchgrass and overall lignin recovery afterpretreatment are shown in Table 16.

TABLE 15 Carbohydrate content of raw and pretreated switchgrassparticles (SWG-1 pretreatment conditions) and overall carbohydraterecovery Raw Pretreated Feedstock Raw Feedstock Output CarbohydratesRecovery chips Input Pulp Liquor Total Soluble Insoluble Total Component(%) (g) (g) (g) (g) (%) (%) (%) Arabinan 3.44 3.44 0.00 0.23 0.23 6.790.00 6.79 Galactan 0.93 0.93 0.00 0.18 0.18 19.48 0.00 19.48 Glucan51.04 51.04 35.88 1.37 37.25 2.68 70.31 72.99 Xylan 26.69 26.69 5.373.01 8.39 11.29 20.14 31.43 Mannan 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 Total: 82.10 82.10 41.26 4.80 46.05

TABLE 16 Lignin input in raw switchgrass particles and lignin fractionsrecovered after organosolv pretreatment (SWG-1 pretreatment conditions)Raw Pretreated Pretreated Feed- Feedstock Feedstock stock Solids LiquidsInput Output Output Component (g) (odw, g) (odw, g) Raw lignin (AIL +ASL) 18.17 — — Self-precipitated lignin (HMW) — —  3.00 Precipitatedlignin* (MMW) — — 10.6  Very low molecular wt. (VLMW) — — — ligninResidual lignin (VHMW) — 2.67 — Total: 18.17 2.67 13.60 *recovered fromthe liquor by precipitation with water; AIL—acid-insoluble lignin;ASL—acid-soluble lignin

The potential of the produced washed switchgrass pulp for production ofethanol was evaluated in 100-mL Erlenmeyer flasks. The experiments inErlenmeyer flasks were run as follows. The pH of the washed pulp wasadjusted with a water ammonia solution to pH 5.50, placed intoErlenmeyer flasks and resuspended in distilled water to a total reactionweight of 100 g (including the yeast and enzyme weight, the finalreaction volume was ˜100 mL) and a final solids concentration of 16%(w/w). The ethanol process was run according to a SSF scheme using afungal cellulase preparation containing all of the enzyme activitiesrequired to depolymerize cellulose at 15 FPU glucan supplemented with afungal beta-glucosidase preparation (30 CBU g⁻¹ glucan) and anethanologenic yeast, Saccharomyces cerevisiae strain Y-1528 at 10 g/Ldry cell wt. capable of fermenting all hexoses. The mixture wasincubated at 36° C., 150 rpm for 48 h. Samples were taken for ethanolanalysis by gas chromatography at 0, 24, 36, and 48 h. The ethanol yieldobtained was 82.51% theoretical ethanol yield based on initial hexoseinput. The final ethanol beer concentration was 5.97% (w/w) (FIGS. 13 aand 13 b).

While this invention has been described with respect to the exemplaryembodiments, those skilled in these arts will understand how to modifyand adapt the systems, processes and equipment configurations disclosedherein for continuously receiving and controllably comminglinglignocellulosic feedstocks with counter-flowing organic solvents.Certain novel elements disclosed herein for processing a continuousincoming stream of lignocellulosic feedstocks with countercurrentflowing or alternatively, concurrent flowing organic solvents forseparating the lignocellulosic materials into component parts andfurther processing thereof, can be modified for integration into batchsystems configured for processing lignocellulosic materials. Forexample, the black liquors produced in batch systems may be de-lignifiedand then a portion of the de-lignified black liquor used to pretreat anew, fresh batch of lignocellulosic materials prior to batch organosolvcooking, while the remainder of the de-lignified black liquor is furtherprocessed into component parts as disclosed herein. Specifically, thefresh batch of lignocellulosic materials may be controllably commingledwith portions of the de-lignified black liquor for selected periods oftime prior to contacting, commingling and impregnating the batch oflignocellulosic materials with suitable organic solvents. Also, it iswithin the scope of the present invention, to provide turbulence withina batch digestion system wherein a batch of lignocellulosic materials iscooked with organic solvents by providing pressurized flows of theorganic solvents within and about the digestion vessel. It is optionalto controllably remove portions of the organic solvent/black liquorsfrom the digestion vessel during the cooking period and concurrentlyintroduce fresh organic solvent and/or de-lignified black liquorsthereby facilitating and expediting delignification of thelignocellulosic materials. It is also within the scope of the presentinvention to further process the de-lignified black liquors from thebatch lignocellulosic digestion systems to separate and further processcomponents parts exemplified by lignins, furfural, acetic acid,monosaccharides, oligosaccharides, and ethanol among others.

1. A modular biorefining process for separating a lignocellulosicfeedstock into component parts and further processing of said componentparts; the modular process comprising: a first processing moduleprovided with a first series of steps for receiving, physicallyscreening, and physico-chemically fractionating a lignocellulosicfeedstock with an organic solvent separately provided thereto therebyextracting component parts therefrom, and separating said componentparts into a first liquid fraction and a cellulosic solids fractioncomprising a plurality of a first class of lignin derivatives therein; asecond processing module provided with a second series of steps forreceiving therein said cellulosic solids fraction and separatingtherefrom a sugar fraction; a third processing module provided with athird series of steps comprising: separating a first solids fractionfrom the first liquid fraction thereby producing a second liquidfraction, said first solids fraction comprising a plurality of a secondclass of lignin derivatives; separating a second solids fraction fromthe second liquid fraction thereby producing a third liquid fraction,said second solids fraction comprising a plurality of a third class oflignin derivatives; recovering from the third liquid fraction at least aportion of the organic solvent and a processed third liquid fraction;and a fourth processing module provided with at least one step forrecovery of a first semi-solid waste material therefrom said processedthird liquid fraction.
 2. A modular biorefining process according toclaim 1, wherein the second series of steps comprises steps forcontrollably reducing the viscosity of the cellulosic solids fraction,controllably digesting the reduced-viscosity de-lignified cellulosicsolids fraction, and recovering therefrom a fourth liquid fractioncomprising at least one sugar.
 3. A modular biorefining processaccording to claim 2, wherein the second series of steps comprises atleast one step for adding an enzyme preparation configured forcontrollably digesting the reduced-viscosity cellulosic solids fraction,said enzyme preparation comprising at least one enzyme selected from thegroup consisting of endo-β-1,4-glucanases, cellobiohydrolases,cellulases, hemicellulases, β-glucosidases, β-xylosidases, xylanases,α-amylases, β-amylases, pullulases, and esterases.
 4. A modularbiorefining process according to claim 3, wherein the second series ofsteps additionally comprises steps for post-digestion recovery andrecycling of a portion of the enzyme preparation.
 5. A modularbiorefining process according to claim 1, wherein the second series ofsteps additionally comprises steps for: commingling the fourth liquidfraction with a microbial inoculum preparation comprising a fermentativemicroorganism; recovering therefrom a fermentation beer; and processingsaid fermentation beer to recover a short-chain alcohol stream and asemi-solid waste therefrom.
 6. A modular biorefining process accordingto claim 5, wherein the microbial inoculum preparation comprises atleast one fermentative microorganism selected from a group containingnaturally occurring and genetically engineered Saccharomyces spp.strains, Pichia spp. strains, Aspergillus spp. strains, Trichoderma spp.strains, Escherichia coli strains, Zymomonas spp. strains, Clostridiumspp. strains, and Corynebacterium spp. strains, and combinationsthereof.
 7. A modular biorefining process according to claim 5, whereinthe second series of steps additionally comprises steps for refiningsaid short-chain alcohol stream to produce one of a fuel-gradeshort-chain alcohol stream and an industrial-grade short-chain alcoholstream
 8. A modular biorefining process according to claim 5, whereinthe short-chain alcohol stream comprises one of an ethanol stream and abutanol stream.
 9. A modular biorefining process according to claim 5,wherein the second series of steps additionally comprises steps forpost-fermentation recovery and recycling of a portion of the inoculumpreparation.
 10. A modular biorefining process according to claim 2,wherein the second series of steps additionally comprises steps forcontrollably commingling with the reduced-viscosity cellulosic solidsfraction for concurrently converting the fourth liquid fraction producedtherefrom into a fermentation beer, a microbial inoculum preparationcomprising at least one fermentative microorganism selected from a groupcontaining naturally occurring and genetically engineered Saccharomycesspp. strains, Pichia spp. strains, Aspergillus spp. strains, Trichodermaspp. strains, Escherichia coli strains, Zymomonas spp. strains,Clostridium spp. strains, and Corynebacterium spp. strains.
 11. Amodular biorefining process according to claim 10, wherein the secondseries of steps additionally comprises steps for recovering thefermentation beer, and processing said fermentation beer to recovertherefrom a short-chain alcohol stream and a semi-solid waste.
 12. Amodular biorefining process according to claim 11, wherein the secondseries of steps additionally comprises steps for refining saidshort-chain alcohol stream to produce at least one of a fuel-gradeshort-chain alcohol stream and an industrial-grade short-chain alcoholstream.
 13. A modular biorefining process according to claim 11, whereinthe short-chain alcohol stream comprises one of an ethanol stream and abutanol stream.
 14. A modular biorefining process according to claim 10,wherein the second series of steps additionally comprises steps forpost-fermentation recovery and recycling of at least one of a portion ofthe microbial inoculum preparation.
 15. A modular biorefining processaccording to claim 12, wherein the second series of steps additionallycomprises steps for post-fermentation recovery of a portion of the firstclass of lignin derivatives therefrom said semi-solid waste.
 16. Amodular biorefining process according to claim 1, wherein the fourthprocessing module is additionally provided with steps for recoveringfrom the processed third liquid fraction, one or more of an aceticacid-containing liquid fraction, a fourth class of lignin derivatives, asugar syrup, and a semi-solid waste material.
 17. A modular biorefiningprocess according to claim 16, wherein a portion of the sugar syrupseparated in the fourth processing module is controllably delivered intothe second module for production of a short-chain alcohol therefrom. 18.A modular biorefining process according to claim 1, additionallyprovided with a fifth processing module configured for receiving andprocessing therein said semi-solid waste material from the fourthmodule, into at least a collectable biogas and a liquid effluent.
 19. Amodular biorefining process according to claim 18, wherein the fifthprocessing module is additionally configured for receiving andprocessing therein a semi-solid waste material from the second module.20. A modular process according to claim 18, additionally provided witha sixth processing module comprising a fermentation module configuredfor receiving, fermenting and distilling therein said sugar syrup, andfor recovering therefrom a distillate comprising at least1,3-propanediol and a lactic acid stream.
 21. A modular processaccording to claim 20, wherein said distillate comprises at least 1,3propanediol.
 22. A modular process according to claim 19, wherein thefifth processing module comprises a first step of biologicallyliquifying said first semi-solid waste material thereby producing afifth liquid fraction, a second step of biologically acidifying thefifth liquid fraction thereby producing a liquid organic acid streamtherefrom, a third step of biologically acetifying the liquid organicstream thereby producing at least acetic acid, and a fourth step ofbiologically producing at least a biogas and a liquid effluent from saidacetic acid.
 23. A modular process according to claim 22, wherein: thefirst step is additionally provided with an inoculation step wherein aninoculum comprising at least one microbial strain selected from a groupcontaining at least naturally occurring and genetically engineeredEnterobacter sp., is controllably commingled with said solid wastematerial; the second step is additionally provided with an inoculationstep wherein an inoculum comprising at least one microbial strainselected from a group containing at least naturally occurring andgenetically engineered Bacillus sp., Lactobacillus sp. and Streptococcussp., is controllably commingled with said fifth liquid fraction; thethird step is additionally provided with an inoculation step wherein aninoculum comprising at least one microbial strain selected from a groupcontaining at least naturally occurring and genetically engineeredAcetobacter sp., Gluconobacter sp., and Clostridium sp., is controllablycommingled with said liquid organic acid stream; and the fourth step isadditionally provided with an inoculation step wherein an inoculumcomprising at least one microbial strain selected from a groupcontaining at least naturally occurring and genetically engineeredMethanobacteria sp., Methanococci sp., and Methanopyri sp., iscontrollably commingled with said at least acetic acid.
 24. A modularbiorefining system for organosolv fractionation of lignocellulosicfeedstock into component parts and further processing of said componentparts, the modular process comprising: a first processing moduleconfigured for receiving, physically processing, and physico-chemicallyfractionating a lignocellulose feedstock by commingling and circulatingtherethrough an organic solvent separately provided thereto, andseparating said component parts into a first liquid fraction and acellulosic solids fraction comprising therein a plurality of a firstclass of lignin derivatives; a second processing module configured forreceiving and processing therein said cellulosic solids fraction, andrecovering therefrom a de-lignified cellulose pulp stream; a thirdprocessing module provided with a third series of steps comprising:separating a first solids fraction from the first liquid fractionthereby producing a second liquid fraction, said first solids fractioncomprising a plurality of a second class of lignin derivatives;separating a second solids fraction from the second liquid fractionthereby producing a third liquid fraction, said second solids fractioncomprising a plurality of a third class of lignin derivatives;recovering from the third liquid fraction at least a portion of theorganic solvent and a processed third liquid fraction; and a fourthprocessing module configured for recovery of a first semi-solid wastematerial therefrom said processed second liquid fraction.
 25. A modularbiorefining system according to claim 24, additionally provided with afifth processing module configured for anaerobic digestion andprocessing of the first semi-solid waste material into at least acollectable biogas and an liquid effluent.
 26. A modular biorefiningsystem according to claim 24, wherein the first processing modulecomprises a plurality of equipment selected and configured forcontrollable and manipulable communication and cooperation for:receiving therein a lignocellulosic feedstock; processing thelignocellulosic feedstock by physically separating non-lignocellulosicmaterials therefrom; physico-chemically hydrolyzing the processedlignocellulosic feedstock by commingling said feedstock with aseparately supplied organic solvent while controllably manipulating atleast the temperature and pressure therein and thereabout, therebyproducing the first liquid fraction and the cellulosic solids fraction;and separately and controllably discharging the cellulosic solidsfraction and the first liquid fraction.
 27. A modular biorefining systemaccording to claim 24, wherein the first processing module is configuredto continuously receive, physically process, and physico-chemicallyhydrolyze a lignocellulosic feedstock thereby continuously producing thecellulosic solids fraction and the first liquid fraction.
 28. A modularbiorefining system according to claim 24, wherein the first processingmodule is configured to receive, physically process, andphysico-chemically hydrolyze a batch of lignocellulosic feedstockthereby producing the cellulosic solids fraction and the first liquidfraction.
 29. A modular biorefining system according to claim 28,wherein the first processing module is provided with atemperature-controllable and pressure-controllable vessel configured to:receive therein the processed lignocellulosic feed stock at about afirst end and to convey said feedstock therethrough to about a secondend; receive therein an organic solvent at about the second end, and toflow said organic solvent therethrough to about the first end; dischargethe cellulosic solids fraction through an outlet provided thereforapproximate the second end; and discharge the first liquid fractionthrough an outlet provided therefor approximate the first end.
 30. Amodular biorefining system according to claim 28, wherein thetemperature controllable and pressure-controllable vessel is configuredto: receive therein the processed lignocellulosic feed stock at about afirst end and to convey said feedstock therethrough to about a secondend; receive therein an organic solvent at about the first end, and tocirculate said organic solvent therethrough and thereabout; dischargethe cellulosic solids fraction through an outlet provided thereforapproximate the second end; and discharge the first liquid fractionthrough an outlet provided therefor approximate the second end.
 31. Amodular biorefining system according to claim 28, wherein thetemperature controllable and pressure-controllable vessel is configuredto: receive therein the processed lignocellulosic feed stock at about afirst end and to convey said feedstock therethrough to about a secondend; receive therein an organic solvent interposed the first end andsecond end, and to circulate said organic solvent therethrough andthereabout; discharge the cellulosic solids fraction through an outletprovided therefor approximate the second end; and discharge the firstliquid fraction though an outlet provided therefor approximate the firstend.
 32. A modular biorefining system according to claim 24, wherein thefirst processing module is additionally provided with equipmentconfigured to sequentially saturate and de-saturate the processedlignocellulosic feedstock with an organic solvent prior tophysico-chemically hydrolyzing said processed lignocellulosic feedstock.33. A modular biorefining system according to claim 24, wherein thesecond processing module comprises a plurality of equipment selected andconfigured for receiving therein the cellulosic solids fractioncomprising a plurality of the first class of lignin derivatives,controllably de-lignifying said cellulosic solids fraction, and recoveryof a de-lignified cellulosic pulp.
 34. A modular biorefining systemaccording to claim 33, wherein the second processing module comprisesequipment configured for de-lignifying the cellulosic solids fractionwith a bleaching process.
 35. A modular biorefining system according toclaim 34, wherein the bleaching process is one of an elementalchlorine-free (ECF) bleaching process and a total chlorine-free (TCF)bleaching process.
 36. A modular biorefining system according to claim33, additionally configured for decrystallization of the de-dignifiedcellulosic pulp stream
 37. A modular biorefining system according toclaim 33, wherein the second processing module is additionallyconfigured for recovery and processing of at least a portion of saidfirst class of lignin derivatives.
 38. A modular biorefining systemaccording to claim 33, wherein the second processing module additionallycomprises a plurality of equipment selected and configured for:receiving therein the de-lignified cellulosic pulp stream; reducing theviscosity of the de-lignified cellulosic pulp stream; enzymaticdigestion of the reduced-viscosity de-lignified cellulosic pulp streamthereby producing a first carbohydrates liquid stream; and recoverytherefrom of the first carbohydrates liquid stream and a first spentsolids fraction.
 39. A modular biorefining system according to claim 38,additionally configured for recovering at least one of a portion of thefirst carbohydrates liquid stream and a portion of the first spentsolids fraction, said portions comprising a plurality of enzymemoieties, and for recycling said portions comprising a plurality ofenzyme moieties.
 40. A modular biorefining system for organosolvfractionation of lignocellulosic feedstock into component parts andfurther processing of said component parts; the modular processcomprising: a first processing module configured for receiving,physically processing, and physico-chemically fractionating alignocellulose feedstock by commingling and circulating therethrough anorganic solvent separately provided thereto, and separating saidcomponent parts into a first liquid fraction and a cellulosic solidsfraction comprising therein a plurality of a first class of ligninderivatives; a second processing module configured for receiving andprocessing therein said cellulosic solids fraction, and recoveringtherefrom a sugar fraction; a third processing module provided with athird series of steps comprising: separating a first solids fractionfrom the first liquid fraction thereby producing a second liquidfraction, said first solids fraction comprising a plurality of a secondclass of lignin derivatives; separating a second solids fraction fromthe second liquid fraction thereby producing a third liquid fraction,said second solids fraction comprising a plurality of a third class oflignin derivatives; recovering from the third liquid fraction at least aportion of the organic solvent and a processed third liquid fraction;and a fourth processing module configured for recovery of a firstsemi-solid waste material therefrom said processed second liquidfraction.
 41. A modular biorefining system according to claim 40,wherein the second processing module comprises a plurality of equipmentconfigured for controllably and manipulably: receiving therein thecellulosic solids fraction discharged from the first processing module;controllably reducing the viscosity of the cellulosic solids fraction;enzymatically digesting the reduced-viscosity de-lignified cellulosicpulp stream thereby producing a second carbohydrates liquid stream; andrecovering therefrom a second carbohydrates liquid stream comprising thesugar fraction and a third spent solids fraction.
 42. A modularbiorefining system according to claim 41, wherein the second processingmodule is additionally configured for recovering at least one of aportion of the second carbohydrates liquid stream and a portion of thethird spent solids fraction, said portions comprising a plurality ofenzyme moieties, and for recycling said portions comprising a pluralityof enzyme moieties.
 43. A modular biorefining system according to claim41, additionally configured for fermenting said second carbohydratesliquid stream, and recovering therefrom a second fermentation beer. 44.A modular biorefining system according to claim 43, additionallyconfigured for separating therefrom the second fermentation beer, asecond short-chain alcohol stream and a fourth spent solids fraction.45. A modular biorefining system according to claim 44 additionallyconfigured for recovering a portion of the second fermentation beer,said portion comprising a plurality of fermenting microorganisms, andfor recycling said portion of the second fermentation beer.
 46. Amodular biorefining system according to claim 44, additionallyconfigured for refining the second short-chain alcohol stream into oneof a fuel-grade alcohol stream and an industrial-grade alcohol stream,and recovering a second aqueous waste stream.
 47. A modular biorefiningsystem according to claim 44, wherein the second short chain alcoholstream is one of an ethanol stream and a butanol stream.
 48. A modularbiorefining system according to claim 47, additionally configured forde-toxifying the second waste aqueous stream, and for reducing theviscosity of the de-lignified cellulosic pulp stream therewith thede-toxified second waste aqueous stream.
 49. A modular biorefiningsystem according to claim 44, additionally configured for recoverytherefrom the fourth spent solids fraction, at least a portion of thefirst class of lignin derivatives.
 50. A modular biorefining systemaccording to claim 41, wherein the second processing module is providedwith a vessel for containing therein concurrent enzymatic digestion ofthe reduced-viscosity cellulosic solids fraction and fermentation of thesecond carbohydrates liquid stream produced therefrom.
 51. A modularbiorefining system according to claim 40, wherein the third processingmodule is additionally configured for recovery of furfurals concurrentwith recovery of the portion of the organic solvent.
 52. A modularbiorefining system according to claim 51, wherein the recovered portionof organic solvent is recycled into the first processing module.
 53. Amodular biorefining system according to claim 52, wherein the recoveredportion of organic solvent is blended with a portion of the short-chainalcohol stream recovered in the second processing module.
 54. A modularbiorefining system according to claim 53, wherein the short-chainalcohol stream is an ethanol stream.
 55. A modular biorefining systemaccording to claim 40, wherein the fourth processing module isadditionally configured for recovering therefrom processed third liquidfraction, one or more of an acetic acid-containing liquid fraction, acarbohydrates syrup fraction, a portion of the fourth class of ligninderivatives, and a second semi-solid waste material.
 56. A modularbiorefining system according to claim 55, wherein a portion of thecarbohydrates syrup fraction is controllably delivered into the secondmodule for production of a short-chain alcohol therefrom.
 57. A modularbiorefining system according to claim 40, additionally provided with afifth processing module comprising a plurality of equipment configuredfor: receiving and biologically hydrolyzing therein the semi-solid solidwaste material separated by the fourth processing module therebyproducing a third liquid fraction; recovering and biologicallyacidifying therein the third liquid fraction thereby producing abiologically acidified liquid fraction; recovering and biologicallyacetifying therein the biologically acidified liquid fraction therebyproducing at least acetic acid; recovering the acetic acid; andbiologically producing at least a biogas and a liquid effluent.
 58. Amodular biorefining system according to claim 57, wherein the fifthprocessing module is additionally configured for controllably receivingtherein a portion of the carbohydrates syrup fraction separated in thefourth processing module, and commingling said portion of thecarbohydrates syrup fraction with the third liquid fraction.
 59. Amodular biorefining system according to claim 57, wherein the fifthprocessing module is additionally configured for controllably receivingtherein the second semi-solid waste material.
 60. A modular biorefiningsystem according to claim 57, additionally provided with a sixthprocessing module configured for receiving, fermenting and distillingtherein said carbohydrates syrup fraction separated in the fourthprocessing module, and for separating therefrom a distillate.
 61. Amodular biorefining system according to claim 60, wherein saiddistillate comprises at least 1,3 propanediol.
 62. A modular biorefiningsystem according to claim 60, wherein said distillate comprises at leastlactic acid.